There’s something timeless about a fabric badge, a small piece of craftsmanship that carries a big impact. Both embroidered and woven badges are durable and versatile, with the intricacy of an embroidered badge or the precision of a woven badge. In this guide, we’ll take you through the process of choosing the perfect fabric badge/patch for your project.
What's the Difference? Embroidered vs. Woven Badges
Embroidered
Woven
Stitches raised above the background fabrics.
Made by weaving threads together rather than stitching to a fabric.
The stitching has a raised feel.
The surface of the final badges is flat and smooth.
Less detail than a woven badge, but has a much more traditional feel.
Because the threads themselves are finer, it is possible to achieve much greater detail than with embroidery.
There are several hundred thread colours to choose from.
There are thousands of thread colours to choose from.
Embroidered badges are made by stitching designs in threads onto a substrate (fabric base). Once stitched, the badge is cut to shape and finished with a backing (iron on or Velcro) and often a merrowed (overlocked) edge. The embroidery adds an additional dimension, creating a 3D badge with raised designs.
Best for: Bold designs, logos, when texture is desired.
Woven badges are made by weaving different colour threads together to form the design. Instead of having a fabric base, the woven threads create the background and the image. The badges have a flat, smooth surface
Best for: Intricate designs, small text, photographic realism.
Printed badges are created by transferring your design directly onto fabric using methods like screen printing, digital printing, or sublimation. Unlike embroidered or woven badges, printed badges allow for full-colour designs, gradients, and photographic detail without the limitations of thread count.
Best for: Complex designs, photographic logos, and promotional merchandise where detail and colour vibrancy are key.
Attachment Methods: How to Apply Your Fabric Badges
- Use a brand-new, sharp needle to make sewing easier and achieve cleaner stitches.
- Choose a thread colour that closely matches the edge of the badge, or a contrasting colour if you want a decorative look.
- Pin the badge securely in place before sewing to prevent movement and ensure correct positioning.
- Make sure you only stitch through the patch and the intended layer of fabric to avoid sewing parts together accidentally.
- Sew with small, neat stitches close to the edge of the badge for a strong and professional finish.
- Finish by knotting the thread on the underside of the garment so the front looks tidy and polished.
- Lay the garment flat on a heat-proof surface, position the badge where you want it, secure it, and remove any lint or dust.
- Set the iron to a heat level suitable for the fabric, usually hot for cotton or cotton blends and slightly cooler for delicate materials.
- Avoid using heat on fabrics like nylon, silk, or leather, as these should be sewn rather than ironed.
- Place a protective layer, such as parchment paper or a thin cloth, between the iron and the badge.
- Apply firm, even pressure with the iron to the badge, either from the front or through the inside of the garment, without moving the iron side to side.
- Hold the iron in place for 20–30 seconds, check adhesion, and repeat if necessary until the badge is secure.
- Allow the garment to cool completely before handling or wearing it.
- Wait at least 24 hours before washing, then wash gently and avoid tumble drying if possible.
Velcro Backing: The Versatile & Removable Option
Velcro backing uses a hook-and-loop fastening system that allows patches to be easily attached, removed, and swapped without damaging the garment. This makes it an ideal option for uniforms, workwear, or tactical gear where badges may need to be changed regularly. Practical and reusable, Velcro-backed patches offer flexibility while still providing a secure hold when in place.
Design Considerations for Embroidered & Woven Badges
The Importance of Merrowed Borders
A merrowed border is created using overlocking stitches that wrap fully around the edge of a badge, sealing it neatly and preventing fraying. This type of border gives the badge a clean, finished look, allowing it to be sold or displayed on its own without needing to be attached to a garment. The raised stitching also adds durability and a traditional, high-quality appearance, making merrowed borders a trusted sign of well-made badges.
Thread Count and Detail
Thread count directly affects how sharp and detailed a badge appears, with higher thread counts allowing for finer lines, smoother gradients, and clearer text. This is especially important for woven badges, where increased thread density enables more intricate designs and a more polished, professional finish.
Translating Your Digital Design to Thread
When converting a digital design into a stitched badge, simplifying fine details, limiting colour choices, and using strong contrast helps ensure the final result remains clear and legible. Choosing appropriate font sizes and avoiding overly thin lines will also improve readability once the design is translated from screen to thread.
Colour, Detail, and Fabric for Printed Badges
Printed badges offer freedom in design that embroidery or weaving can’t match. You can include complex gradients or more vibrant colours or designs.
Inspiration Gallery: Fabric Badges in Action
For Sports Clubs and Teams
Frequently Asked Questions (FAQ)
- Can you create a badge in any shape? Yes! For badges with complex shapes, we often recommend a heat-cut border, but not all custom shapes require it. The key factor is whether the internal angles are too sharp for the overlocker to follow the outline. Heat-cut badges are precision-cut with a laser, leaving no wrap-around border, which allows for very intricate designs. For embroidered badges, a non-wrap-around border can still be stitched on the front for a polished finish.
- What is the best file format for my design? We can accept artwork in almost any format, but what we really like is a fairly high resolution jpg (300 dpi), or an eps or pdf. If you are in any doubt, just email your artwork through and we’re sure we’ll be able to work it out. For embroidered and woven badges, we can even turn hand-drawn sketches or doodles into a finished badge design.
- How do I care for my embroidered/woven badges? Hand wash gently with mild detergent and cold water, or use a delicate machine cycle. Avoid high heat, bleach, or harsh chemicals. If ironing is needed, use a low setting with a protective layer in between the iron and your badge. We usually suggest parchment paper or a thin tea towel. Store flat in a cool, dry place to prevent fading or warping.
What is the minimum order? The minimum order quantity for both woven and embroidered badges on our website is 100pcs. While we can provide a sample of 4pcs, this may incur an additional cost. Please contact us and one of our customer service advisors will be happy to help.
- Are printed badges as durable as embroidered or woven? While printed badges excel in color and detail, embroidered badges are generally more durable for heavy-duty use. Printed badges are ideal for casual wear, promotional items, and lightweight applications.
Start Your Embroidered Badge Project Today
Take a look at the embroidered badges we offer in our shop. Shop Embroidered Badges
Still Undecided?
Fill out our contact form. Contact Us for Custom Orders
Order one of our Fabric Badge Sample Packs to see the differences between embroidered and woven badges in person.
