Design Your Own Patch | The Complete Guide to Custom Patch Design

If you are looking to design your own patch, you are in the right place. We will be talking about sizes, placements, colors, backings and more….

We can provide you with a custom design for your embroidered patch at no cost. In order to help you decide on the elements involved in an embroidered patch order, please follow the following links:

1. The Right Size for Your Patch

There is no average patch sizes since every patch we create is custom made to order. Our sales reps can offer popular sizes of patches done in the past.  Many times we let the artwork or design idea dictate the size that will work best for your custom embroidered patch.

Below is a list of common standard patch sizes we have made in the past:

  • Military Patch
  • Shoulder Shield: 3.5-4”
  • Chest Shield 3-3.5”
  • Rectangle Tab: 3”x1” or 3”x2”
  • Circle: 3” round

2. Choosing Colors For Your Patches

The most common standardized color system in the world is the Pantone Matching System (PMS) widely used in the printing business, which produces chips and booklets made to match your colors to one of their own. We use one of these booklets to match the specified colors and then match to the closest thread/twill color available to us, therefore we cannot guarantee 100% color matching, we can just give you our own closest match.

Select your Thread and Twill Charts.

3. Common Patch Shapes & Templates

We can make your patches in any shape, even wraparound your patch design!

However, if you are in need of inspiration or ideas for your patches, we have compiled a little chart of the most common shapes requested.


rocker template patch design

Tabs (Squares & Rectangles)

tab template


shield template


tombstone template


wedges template design your own patch

4. How to Attach Your Patches (Backing Options)

We have options to choose from for all your patch needs.

The type of backing you choose for your custom patch order can contribute to the overall cost.

patch plain backing
patch velcro backing
Velcro Patches 2-Sides

5. Types Of Borders

Your patch has two options for border type. Depending on the shape your art is will determine what type of border is possible.

Merrow Border (standard)

Merrow Border

Merrow Border (standard) is typical on simple shapes such as round, shield, square or rectangles. This type of border seals the edges of your patch with actual thread by stitching around the edge of the patch from front to back until the entire outer edge has been finished.

The thinnest Merrow Border possible is 3mm (~1/8″)

laser cut border
Laser Cut

Laser Cut Border

It is used if you patch design is geometric or has a complex shape with sharp edges to it. This type of border seals the edges by “heat sealing the patch threads so they are sealed to prevent thread fray. This melted edge is not clear to the naked eye.

The thinnest Laser Cut Border is 1mm (~3/64″)

6. Fonts For Small & Medium Size Patches

6. Fonts For Small & Medium Size Patches

Let’s Get Started

If you are thinking about ordering your Custom Patches, just fill out our simple quote request form, our expert Sales Reps will get back to you within 24 business hours and guide you through every step of the process.

sienna pacific - custom promotional products