Flat Embroidery
A classic stitched finish for logos, lettering and everyday badges. Common uses include uniforms, jackets, caps and bags.
Custom patches
Custom Embroidered Patches
Custom embroidered patches made to your artwork, finished size and thread colours, supplied as separate patches for caps, jackets, uniforms and bags. Artwork is reviewed at its intended finished size before we quote.
MOQ50 pcs per design
Stitch styles
What we can embroider for you
Each style below is a construction we actually produce. Stitch type, coverage and finished size are confirmed against your artwork before quoting, because they change how a logo reads at its real size.
3D Puff Embroidery
Foam-supported embroidery for raised elements. Suitable shapes, stitch structure and finished size need review; often considered for bold cap logos.
Full Coverage Embroidery
Thread covers the patch face for a dense stitched appearance. Coverage is a construction choice, not a separate guarantee of quality; confirm it with the artwork.
Metallic Thread Embroidery
Reflective thread accents for decorative emblems and commemorative badges. Thread availability, stitch density and fine detail are evaluated for the project.
Fine-Detail Embroidery
An artwork-led approach to finer lettering and closely spaced elements, not a universal precision specification. Readability is checked at actual size; changes or woven construction may be recommended.
Custom-Shaped Embroidery
An outline tailored to the artwork. Narrow sections, internal corners and complex contours are reviewed with the border and backing.
Manufacturing evidence
Photographed in our own workshop
The photographs below were taken in the workshop where these patches are embroidered. Each caption states what that picture shows, and operations photographed separately are not one customer order.
Multi-head embroidery line
RAYSUN production photograph
Backing process station
RAYSUN production photograph
Thread colour check
RAYSUN production photograph
Artwork preparation
RAYSUN photograph
Patches are mainly produced in-house. Special processes, materials or capacity requirements may involve outside partners; RAYSUN remains responsible to the customer for quality and delivery. The photographs show existing colour-check, embroidery and backing operations; they are not consecutive stages of one customer order.
Quality control
The inspection stages between artwork and dispatch
Inspection happens at fixed points in production rather than once at the end. The steps below run in the order shown, and each one states what is checked and against what.
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Artwork review
Artwork, finished size, lettering and construction are reviewed for feasibility before anything is stitched.
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Pre-production sample
A sample confirms stitch, colour and structure against the approved artwork.
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In-process inspection
Stitching is checked during production rather than only at the end of the run.
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Edge and backing inspection
The edge finish and the backing are checked against the approved specification.
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Final inspection
Appearance, dimensions, quantity and packing are checked against the approved reference.
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Bulk consistency
The bulk run is compared with the approved sample so the order stays consistent from the first piece to the last.
Detail & stitch density
How much detail the stitching holds
Detail is limited by patch size, thread and construction. Where a project has both the artwork and the finished patch photographed, the pair is published here side by side.
Very fine text and tightly spaced detail can close up at small sizes. We check the smallest readable element against your artwork at the finished size before quoting, and may suggest a larger patch or a woven construction where the detail would not survive. Detail depends on finished size, thread and construction, so not every detail seen on screen reproduces exactly.
Coverage & base fabric
What thread coverage changes
Coverage is how much of the surface the stitching fills. Low coverage leaves the base fabric visible for a lighter face; high coverage fills the patch face. Each level is photographed on its base fabric once that sample is available.
Low coverage
Partial stitching leaves the base fabric visible behind the design, for a lighter, more textured face.
Medium coverage
A mix of stitched and open areas, where the design allows the base fabric to show through.
High coverage
Thread covers the patch face for a dense, even stitched appearance where the artwork needs it.
Coverage is a construction choice, not a quality grade. Thickness and softness also depend on the base fabric, thread, stitch density and structure, so higher coverage alone does not make a patch harder.
Certificates & reports
Documents you can ask us for
Edge finishing
How the outline is finished
The edge decides how the badge sits against fabric and how sharp an outline can be. Where a finish has front, back and macro photographs, each is shown separately rather than cropped into one picture.
Merrow / Overlock Border
A wrapped, raised edge for a traditional badge finish. Simple outlines often suit this construction; tight internal corners may need another treatment.
Laser-Cut Edge
A closely cut outline for custom shapes. Check the material, contour and edge appearance during artwork review or sampling.
Stitched Border
An embroidered border following the outline. Border width and stitch treatment are confirmed with the production artwork.
Backing options
How the patch is attached
Backing is chosen for the surface the patch goes on and for who installs it. Heat-activated backing is not automatically suitable for coated, waterproof or heat-sensitive fabric: we confirm the method and test it on the actual material.
Sew-On
Permanent attachment by stitching. Confirm fabric compatibility and the installation method with the garment or accessory maker.
Iron-On / Heat-Seal
Heat-activated backing. Temperature, time, pressure and fabric compatibility require confirmation; test on the actual material.
Hook-and-Loop
For removable or interchangeable patches. Confirm whether a matching loop piece is needed and how it will be installed.
Self-Adhesive
Suitability depends on the surface and the intended duration. Do not assume permanent or washable performance.
Size & shape
Shapes we cut and where they fit
Size is quoted in millimetres or inches across the finished edge, measured against the actual cap, garment or bag. A larger patch holds more detail; a smaller one needs the artwork simplified.
Round / Circular
A circular outline for a single emblem; the finished size is set from the installation area.
Square
Straight edges hold block lettering and balanced logos.
Rectangle
A wide outline for name bars and horizontal logos.
Oval
A softened outline for emblems and titles that need more width than height.
Shield / Crest
A shaped outline for club, school and uniform emblems; internal corners are reviewed together with the border.
Custom die-cut
An outline traced from your artwork. Narrow sections and tight contours are reviewed with the edge finish.
Size is quoted across the finished edge and checked against the actual installation area. Minimum and maximum sizes are published only once production has confirmed them for the construction, so ask for a size review together with your artwork.
Thread colour
Matching thread to your colour reference
Thread is matched to a physical reference rather than to a screen. A Pantone number narrows the search to the nearest thread we can supply; for a critical colour we agree a physical swatch and an acceptable variation before production.
Pantone is used as a matching reference, not a guarantee of an exact match to a paper card, and a screen RGB value does not represent the thread colour. For critical colours we agree a physical reference and an acceptable variation before production.
Applications
Where an embroidered patch is worn
A patch is chosen alongside the item it goes on: position, finished size, edge and backing follow from the garment or bag rather than from the artwork alone.
Caps & Hats
Front panels and side placement. The curve of the cap limits the usable area, so the artwork is checked against the panel before sizing.
Jackets & Apparel
Chest, sleeve and back placement. Heat-seal or sewing is chosen together with the garment maker.
Backpacks & Bags
Front panels and lid placement. On coated or heat-sensitive fabric the attachment method is checked on the material itself.
Uniforms & Workwear
Repeatable emblems across sizes and batches, with one approved reference held for reorders.
Promotional & Event Merchandise
Small runs of event badges and souvenir patches, often with several designs in one order.
By industry
What each industry buys and how the patch is built
Buying habits differ by sector: a uniform programme, a promotional order and a resale line do not ask for the same construction. Each entry below pairs typical needs with the build we would propose for them.
Fashion
Key focus
Typical purchasing needs
Design-led badges that carry a brand mark, often in several colourways.
Recommended construction
Full-coverage embroidery or metallic accents, with the smallest lettering reviewed at finished size.
Uniform
Key focus
Typical purchasing needs
Consistent emblems across sizes, batches and reorders.
Recommended construction
Merrow border with sew-on backing, held against one approved sample.
Promotional
Key focus
Typical purchasing needs
Event and gift badges, usually several designs in one order.
Recommended construction
Flat embroidery with hook-and-loop or iron-on backing for fast distribution.
Outdoor
Brief introduction
Typical purchasing needs
Badges for packs, bags and outerwear, where the item is used hard.
Recommended construction
Coverage and edge chosen with the abrasion the item sees in use.
Tactical & Military
Brief introduction
Typical purchasing needs
Structure and function come before decoration.
Recommended construction
Shaped construction and removable attachment, confirmed against the unit's specification.
Buying questions
Frequently asked questions
These are the questions that come up before an order is placed. If yours is not here, ask it with your quote request and we will answer it directly.
What is the difference between embroidered and woven patches?
Embroidery gives a raised stitched surface with a traditional badge look; woven patches have a flatter, finely woven surface and are often considered when small lettering and thin lines must stay crisp. Compare both against your artwork at its finished size.
What backing options are available?
Sew-on, iron-on (heat-seal), hook-and-loop and self-adhesive. The right one depends on the surface and on who installs the patch; heat-seal compatibility is confirmed on the actual material rather than assumed.
What edge finishes can I choose?
Merrow (overlock), laser-cut and stitched borders. Simple outlines often suit a wrapped edge; tight internal corners and complex contours are reviewed during artwork review or sampling.
Can you match Pantone colours?
Thread is matched to a Pantone reference as closely as the available thread allows. It is a reference, not a guarantee of an exact match to a paper card, and a screen RGB value does not represent the thread colour. For critical colours we agree a physical swatch and an acceptable variation.
What size should I choose for hats or jackets?
Measure the installation area on the actual cap or garment and give the width and height across the finished edge. There is no universal size: a larger area holds more detail, and the artwork is checked at your stated size before quoting.
Can small text and detailed logos be embroidered?
Bold shapes, lettering and mid-size detail embroider well. Very fine text and tightly spaced detail can close up at small sizes, so we check the smallest readable element against your artwork and may suggest enlarging the patch or choosing woven construction.
What is the MOQ?
50 pcs per design. Different designs, sizes and colour versions are evaluated separately rather than automatically combined to reach the minimum.
Can I receive a sample before bulk production?
Not every project needs a physical sample, but the production reference must be explicitly approved. Physical samples usually carry a fee, and any credit against a bulk order is agreed per project before sampling starts.
What is the production lead time?
Timing depends on approved artwork, payment conditions, construction, quantity and how many designs the order contains. Sample completion, production completion and dispatch are confirmed as separate dates; international transit and customs come on top, so a production date is not a delivered-by promise.
Can you arrange shipping to my country?
We can arrange express or freight, or work with your nominated forwarder. Product price, freight, duties and taxes are confirmed separately in the quotation; ask your own broker to confirm the import treatment for your destination.
Start your quote
Send your artwork and project details
Artwork is reviewed at its intended finished size before we quote, so the reply covers the construction that will actually work rather than a price per patch. Vector artwork helps; a clear photo or sketch is enough to start.
To prepare your quotation
- Artwork file: AI, PDF or a high-resolution JPG / PNG
- Finished width and height in mm or inches
- Quantity per design — MOQ 50 pcs
- Preferred stitch style and thread colours
- Edge finish, backing and the intended application
- Target delivery date and destination country
- Packing requirements and any physical sample request
MOQ50 pcs per design
- Email [email protected]
- Phone +8613527731683
- WhatsApp +8613527731683