How Are Woven Patches Made? A Step-by-Step Guide

How Are Woven Patches Made?

Custom woven patches are one of the most versatile and detailed patch options available today. They offer a sleek, high-resolution look, making them perfect for designs with fine details and intricate designs. But how are woven patches made, and what sets them apart from custom embroidered patches?

In this guide, we’ll journey through the entire process, from design to production. So you can understand what goes into producing these stylish, durable patches.

What Makes Woven Patches Different?

Before we dive into the process, let’s dive into what makes woven patches unique. Unlike the textured feel of embroidered patches, which use thicker thread stitched with an embroidery machine over the cotton twill base material, woven patches are created by interlacing thin threads to form flat patches with finer details. This creates a flatter appearance and decreases the thickness of the patch but adds cleaner lines and a sharp look.

✅ Sharper details – Fine Lettering, crisp lines with smooth texture.
✅ A smooth surface – No thick thread means a sharp, sleek look.
✅ Higher thread count – Similar to how woven fabrics are made, these patches use tighter weaves for a wonderful visual appeal.
✅ Greater flexibility – They are thinner and lightweight compared to embroidered patches.

Now, let’s see how to turn a custom design into a woven patch:

Step 1: Designing the Patch

Every custom patch starts with a design. Whether it’s a company logo, sports team design, or military patch, the artwork must be converted into a digital format suitable for weaving.

Since woven patches use thinner threads than embroidery, they can accommodate intricate details and small lettering. But, there are still limitations. Some designs require simplification for clarity. Most importantly, woven labels with small text or a lot of text.

A graphic designer will adjust your artwork, mapping out every thread placement to ensure an accurate final product. This digital file serves as the blueprint for the patch.

Step 2: Selecting Colors and Size of the Patch

Unlike printed patches, where the production process involves dying a piece of fabric, custom woven patches are created using colored threads woven together. Choosing the right thread colors is crucial because shading and gradients are achieved through a mix of overlapping threads rather than embroidery’s thicker stitching. But true gradients are not possible.

If you require a true color gradient, we suggest dye-sublimated patches. The production process for sublimated patches is ink dying into the thread. This created a printed look and is much different from the woven patch look.

Most woven patches are made using high-quality polyester threads, which are known for an array of customization options, which include:

✔ Vibrant colors – Threads don’t fade easily, even after multiple washes.
✔ Durability – Due to the tight weave, they withstand wear and tear.
✔ Lightweight feel – Woven patches are thinner than embroidered patches, making them ideal for clothing brands and professional uniforms.

When selecting a size, think about what you are using the patches for. Are you creating football patches or baseball patches? Then, you want to make sure the size is optimal for a sports uniform.

Once the colors are selected, the weaving process begins.

Step 3: Weaving the Patch Design

This is where the magic happens! Unlike other patch types, like chenille patches, where raised threads are stitched onto fabric, woven patches are produced on specialized looms that weave the design directly into the patch.

Here’s how it works:

🔹 Complex interlacing at high speeds, forming a tight fabric patch.
🔹 The design is built into the patch itself. No needle stitching is required. This is when text clarity is checked.
🔹 Because of this technique, woven patches can achieve a high thread count, meaning complex designs.

The weaving process results in a smooth and flexible patch with clean lines. Great for logos, smaller labels, and detailed designs.

Step 4: Cutting and Shaping the Patch

Once the patch is woven, it must be cut to shape. There are a few cutting methods, depending on the desired finish:

• Laser Cutting: For precise, custom shapes with clean edges.
• Heat Cutting: Seals the edges, then the border is embroidered to frame the patch nicely.
• Merrowed Edge: Thicker style merrow clipped to the border.
  
  Each method ensures the patch retains its shape and durability over time. The most popular and cost-effective option is the merrow borders.

Step 5: Adding the Backing

Based on the purpose the patch is being used for, there are different backing options to choose from:

🔹 Iron-on backing – Ideal for easy heat application. Creates a custom iron-on patch.
🔹 Hook and loop backing (velcro backing) – Great for military, tactical, and law enforcement patches. Common for airsoft patches as well.
🔹 Adhesive backing – A great way to hold the patch in place for sewing.
🔹 Sew-on backing – The most secure, long-lasting option.

The choice of backing depends on how the patch will be used, whether it’s for uniforms, promotional merchandise, or fashion branding.

Step 6: Final Quality Check & Packaging

Before shipping, every style of patch goes through a rigorous quality control process. Manufacturers check for:

✔ Thread consistency – Ensuring no loose or uneven weaving.
✔ Color accuracy – Matching the final product to the approved design.
✔ Shape and edge quality – Verifying precise cutting and finishing.

Once approved and passed quality control. The patches are packaged and shipped, ready for brands and individuals to use for their custom apparel and promotional items.

Why Choose Woven Patches?

Woven patches have become a top choice for brands and organizations due to their durability and high-quality finish. Here’s why they stand out:

🔹 Great for small details – Perfect for logos and designs with small text.
🔹 Flexible and lightweight – Comfortable for clothing and accessories.
🔹 Professional and stylish – Offers a polished look for any brand or uniform.

Whether you’re designing custom apparel, uniforms, or promotional products, woven patches provide a sleek and long-lasting branding solution. They can withstand frequent use, and they look incredible.

Get High-Quality Woven Patches with The Monterey Company

At The Monterey Company, we specialize in crafting custom products tailored to your brand’s needs. Whether you need them for events or uniforms, our team ensures every patch has that professional look. We don’t just produce woven patches, either! We offer other types of patches like leather patches, PVC patches, Hat Patches, and more.

✨ Why work with us?
✔ 35+ years of experience in custom patches
✔ High-quality materials and great service
✔ Fast production times and low cost

📩 Ready to bring your design to life? Contact us today for a free quote and digital proof. Let’s create the perfect woven patch for your brand! Ask your customer service rep for free samples of woven patches! Free shipping for samples as well (United States only for free samples).

Final Thoughts

Now that you know how woven patches are made, it’s easy to see why they are a popular choice in so many industries. Their ability to capture intricate details with a professional finish makes them a top-tier branding option.

Still have questions? Drop us a message—we’d love to help you create your custom-woven patches! Make sure to sign up for our newsletter at the bottom of the page with your email address for free promotions.