Patch Showdown: Woven vs. Embroidered Patch

When it comes to custom patches, choosing between woven vs embroidered patch styles can feel overwhelming. Both offer unique benefits, and each one is suited for different types of designs, applications, and budgets. At The Monterey Company, we’ve helped customers navigate this decision for decades by breaking down the key differences—so you can make an informed decision and end up with the perfect patch for your needs.

Whether you’re designing for sports teams patches, uniforms, or fashion branding, understanding how these different types of patches are made—and what sets them apart—can help you select the best option for your project.

Woven Patches: Clean Lines & Fine Detail

Woven patches are made by weaving thinner threads together using a tight weave technique. This method creates a smooth surface with no raised stitching, making it ideal for highly detailed designs, fine lines, and small details.

Unlike embroidery, woven patches don’t rely on raised threads or thick stitching. Instead, they showcase intricate designs and fine details with crisp precision. That’s why they’re often the better option for designs with a lot of text, finer details, or complex designs.

These patches are also incredibly lightweight and flexible, making them perfect for delicate fabrics like performance wear, custom hats, or soft tees. If you’re looking for something subtle, modern, and polished, woven patches are a great choice.

Common uses for woven patches:

• Corporate logos with small text
• Fashion tags and woven label branding
• Uniform patches that require a flat surface
• Projects needing a lightweight finish with a professional edge

Custom Embroidered Patches: Bold, Classic, and Dimensional

Custom embroidered patches are made by stitching thread onto a fabric backing, creating a raised texture that adds depth and visual impact. This traditional technique offers a three-dimensional look, making it ideal for simple designs and bold artwork. There are even puff embroidered patches for an extreme 3D appearance.

Because embroidery uses thicker threads, it can sometimes lose clarity on highly detailed designs. However, it’s unbeatable when you want that textured feel, rich depth, and classic look that stands out on uniforms, jackets, or tactical gear.

We recommend custom embroidery patches when you want your design to pop off the surface or need a rugged, long-lasting patch for heavy use.

Best uses for embroidered patches:

• Military and police patches
• Sports teams and club logos
• Scout badges and event branding
• Gear bags, jackets, and durable base material

Type of Patch: Which Is Right for You?

If you’re still unsure which type of patch is right, consider the overall look you’re going for and the fabric you’ll be applying it to. Each has its strengths depending on the use case and artwork.

Need help deciding? Our team of experts is happy to provide a sample or recommendation based on your design.

Printed Patches: When You Need Photorealistic Precision

While woven and embroidered patches are incredibly versatile, custom printed patches are another option worth considering—especially when your design includes gradients, shadows, or photographic elements.

Printed patches are made by printing your artwork directly onto a piece of fabric, allowing for vibrant colors, photographic quality, and fine details that embroidery or weaving may not capture. They’re ideal for full-color designs, portraits, or when you want a super-fast production process.

Though they’re less durable than embroidered or woven options, they’re a great option for promotional items or event swag where sharp imagery is key.

Chenille Patches: Soft Texture Meets Retro Vibes

Chenille patches bring back that classic letterman jacket style. These patches are made with thick yarns that create a fuzzy, looped texture. Because of their textured feel and thickerthreads, chenille is typically used for bold letters or simple designs rather than intricate artwork.

While they don’t offer fine details, they add a special, nostalgic look to varsity jackets, school uniforms, and spirit wear.

PVC Patches: Durable, Waterproof & Modern

If you’re looking for a high-quality, modern patch that’s both waterproof and flexible, PVC patches are the answer. Made from soft rubber-like material, these patches can replicate detailed designs with vibrant colors and a clean, polished finish.

They’re commonly used for outdoor gear, tactical equipment, and sports teams who want a durable patch that stands up to the elements.

Leather Patches: Timeless & Stylish

Leather patches (or faux leather options) are a stylish way to elevate your branding. Perfect for hats, bags, or denim, these patches offer a premium look with the ability to be debossed, engraved, or screen printed. They’re typically applied to cotton twill, denim, or other base fabric using heat pressing or stitching.

If your goal is to create a rugged, fashion-forward patch with minimal color and a classic look, custom leather patches are an excellent choice.

Final Thoughts: Making the Best Choice

When choosing between woven vs embroidered patch styles, it all comes down to your design and application. Here’s a quick recap:

• Choose woven patches for fine details, intricate designs, and a smooth surface
• Choose custom embroidered patches for a raised texture, classic look, and thicker threads
• Consider printed patches for vibrant, photorealistic art
• Go with Chenille Patches for retro-inspired boldness
• Pick PVC Patches for all-weather durability
• Use Leather Patches for timeless branding on fashion accessories

Need help finding the best choice for your design? At The Monterey Company, we offer all these customization options and more, backed by decades of manufacturing processes experience and customer trust. Our team is here to make your patch project seamless from start to finish.

Let’s create something special. Contact us today for a quote or sample to bring your idea to life!