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Custom patches

Custom TPU Patches

Custom TPU patches made to your artwork, dimensions and color layout. TPU is a thermoplastic polyurethane, not PVC: material grade, thickness, surface and fixing method are agreed against your artwork and confirmed on the sample we produce.

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The product

What a TPU patch is

A molded part, not a print

The patch body, its outline and any relief come from a tool, so flat areas and raised elements are formed rather than stitched or printed.

Flexibility follows the formulation

TPU is a thermoplastic polyurethane. How much a finished patch bends, and how it feels on a curved surface, follows from the material grade, the thickness and the structure — so it is confirmed on the sample you approve rather than assumed from the material name.

Color in solid areas

Color is laid into the part, and the separation between colors is fixed by the tool. Solid blocks and defined shapes hold; gradients and photographic shading are outside what a molded part carries.

Surface finish decided at tooling

Smooth, matte, finely textured or locally raised surfaces are set when the tool is made, so the finish is agreed before production starts.

One approved tool, a repeatable part

A single approved tool produces the same part across the run, which suits logos repeated across uniforms, bags and merchandise.

Structures

2D, 3D and layered TPU patches

Flat (2D)

One level

The design sits at one level and only color separation creates definition. Suits simple marks, wordmarks and places where the patch must stay low-profile.

Raised relief (3D)

Formed height

Selected elements stand above the base. The relief is defined by the tool, so how much height the artwork can take is reviewed before tooling.

Layered / multi-level

Two or three levels

A background level with one or more elements above it, used when a crest or emblem needs visible separation between its parts.

Material

Patch material

TPU is a thermoplastic polyurethane. Two patches made from it can feel completely different: grade, thickness and structure decide how much the part bends, how it feels in the hand and how it sits on a curved surface.

Because of that we do not publish one hardness or thickness figure for the range. Grade and thickness are agreed against your artwork and the surface it is fixed to, and confirmed on the physical sample you approve.

Color

Color options

Color is laid into the part in solid areas, so each color is a separate element of the tool. Pantone references are used to identify the closest available material color: they are a matching reference, not a guarantee of an exact match, and a screen image never represents the finished color.

For critical colors, agree a physical reference and the acceptable variation before production.

Surface

Surface texture

Smooth

A closed, even surface that shows color separation cleanly.

Matte

A flatter surface that reduces reflection under lighting and photography.

Fine texture

A patterned tool surface used when a fabric-like or technical appearance is wanted.

Locally raised detail

Selected elements formed above the base plane, defined at tooling.

Size & shape

Shapes and sizes

Round or circular

A badge or emblem shape with an even outline; the most tolerant outline for raised elements.

Square or rectangle

Suits wordmarks, name patches and label-style marks.

Shield or crest

A traditional emblem outline; internal corners are reviewed with the tool.

Custom die-cut outline

An outline drawn to the artwork, reviewed for narrow sections and tight internal corners before tooling.

Size, thickness and the smallest detail are evaluated together: a shape with narrow sections and tight corners needs more room than a solid badge of the same width. We do not publish a blanket size or thickness range for TPU parts; the workable minimum and maximum are confirmed against your artwork and stated in the quotation.

Edge

Edge and outline

Formed edge

The outline is set by the tool, so the edge is formed with the part and follows the approved shape.

Edge with a border element

A raised or recessed border separates the artwork from the outline; whether it suits the design is reviewed with the tooling.

Attachment

Backing and attachment options

Sew-on with stitching holes

Permanent attachment by stitching, with holes provided in the part if the design calls for them. Confirm the fabric, thread and who installs the patch.

Hook and loop

For removable or interchangeable patches. Confirm whether the matching loop piece is required and how it is fixed to the item.

Adhesive backing

For flat surfaces and short-term use. Suitability depends on the surface and the intended duration; adhesion on coated or textured materials is confirmed by testing the actual item.

Mold & sampling

From artwork to a finished TPU patch

  1. The artwork is checked at its intended finished size: outline, smallest element, color count and whether the structure you want can carry the design.

  2. Material grade, thickness, surface finish and structure are agreed before any tool is cut, because those choices set the limits of the part.

  3. Where the structure needs a tool, it is developed and reviewed with the artwork and the approved colors.

  4. Samples are produced from the tool and checked for color, dimension, structure and detail.

  5. You approve the physical sample. It becomes the reference for the bulk run, in writing.

  6. Bulk production follows the approved sample and the final specification.

  7. Finished parts and their packing are checked before dispatch.

Tooling and sample charges, the sampling schedule and the lead time are stated in the written quotation for the design. Where a project needs no tool, that step is not charged. Tooling is made for the design it was developed from, so a change of shape or element is reviewed as a new tooling question.

Quality control

Checks at each stage

  1. Artwork and structure review

    Artwork, outline and structure are checked against the approved specification before production starts.

  2. Pre-production check

    The first parts are checked for color, dimension, thickness and detail against the approved reference.

  3. In-process inspection

    The run is checked while it is in production, so a drift is caught before the batch is finished.

  4. Backing and attachment check

    The back of the part and the fixing method are checked: stitching holes, hook-and-loop pairing or adhesive, as specified.

  5. Final inspection

    Appearance, dimension, quantity and packing are checked before dispatch.

  6. Bulk consistency

    The bulk run is compared with the approved sample to confirm it is the same part, not just a similar one.

Certificates & reports

Documents you can ask us for

Applications

Where TPU patches are used

A TPU patch is specified together with the item it mounts to: the mounting area available, the surface material and the conditions the finished product meets decide the backing, the thickness and the relief. Confirm those before a sample is approved.

A badge or wordmark on the front panel, usually fixed by sewing or hook and loop. Size and curve are checked against the actual cap before tooling.

Chest, sleeve and back placements where the part has to sit on fabric that moves; thickness and edge are agreed with the garment maker.

A solid badge on a bag face or lid, where a formed part takes handling better than a flat print. Confirm the surface texture before choosing adhesive.

Repeated marks across a uniform run: one approved tool keeps the part consistent, and the fixing method must suit the fabric and the wash instructions of the garment.

Event and brand-merchandise badges where the shape carries the design; quantity per design and the fixing method shape the quotation.

Industries

What each buying industry needs

Buying habits differ by sector: a uniform program, a promotional run and a resale line do not ask for the same construction. Each entry below pairs what that buyer needs with how we answer it.

Fashion

Key focus

Brand marks where the badge carries the design: color separation, relief and the finish the tool allows are the deciding points.

Uniform

Key focus

Repeated marks across a run: one approved tool keeps the part consistent, and fixing must suit the fabric and wash instructions.

Promotional

Key focus

Event and merchandise badges where shape matters; quantity per design and fixing method shape the quotation.

Outdoor

Brief introduction

Badges on packs and equipment, where the fixing method and the surface are reviewed with the item.

Tactical & military

Brief introduction

Functional marks where the fixing method must be confirmed for the equipment; only projects with real material are shown.

Guides

Read more before you choose

These comparisons explain how one material and one construction differ from another, so the choice is settled before a sample is ordered.

TPU vs PVC vs embroidered vs woven vs heat transfer patches

Five constructions compared on build, artwork limits and fit, with a product-by-product decision guide.

Read the comparison

Custom patch types ranked by use case

The same five constructions ranked separately for caps, uniforms, fine detail, bags and promotional runs.

Read the comparison

How custom patch constructions differ: a technical review

Construction mechanics, artwork limits, attachment and how to verify a supplier's claims.

Read the comparison

FAQ

Purchasing 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 are TPU patches made of?

A TPU patch is a part formed from thermoplastic polyurethane: color is laid into the material and the outline comes from a tool. It is not PVC and not a fabric patch, so the material is named on the specification and confirmed on the sample.

What is the difference between TPU and PVC patches?

They are different polymers with different processing, so they can be compared on artwork, shape, surface and use — but not ranked in the abstract. The same artwork can behave differently in each. Ask for both samples and compare the physical result.

Are TPU patches flexible?

TPU is a flexible thermoplastic polyurethane, but how much a finished patch bends depends on the material grade, the thickness and the structure. That combination is confirmed on the physical sample rather than stated as a general property.

What thickness and hardness options are available?

We do not publish one hardness or thickness figure for the range, because the workable values follow from the artwork, the shape and where the patch is fixed. The values for your design are confirmed in the sample stage and stated in the quotation.

Can you make 2D and 3D TPU patches?

Flat, raised and layered structures are reviewed against your artwork. Relief is decided when the tool is made, so how much height a design can take is agreed before tooling starts.

Can you match Pantone colors?

Pantone references are used to identify the closest available material color. They are a matching reference, not a guarantee of an exact match, and a screen image never represents the finished color. For critical colors, agree a physical reference before production.

What backing and attachment options are available?

Sew-on with stitching holes, hook and loop, and adhesive backing. The method is chosen for the surface the patch sits on and confirmed against the actual item, since adhesion and stitching both depend on the material.

Can TPU patches be heat-applied?

Only after the fabric, temperature, pressure and dwell time have been confirmed to suit the TPU part. Heat application is not offered as a standard option: it is evaluated on the actual material first, and where the fabric cannot take it we recommend sewing or another fixing method.

Do TPU patches require a mold or tooling?

Molded structures need a tool. Whether your design needs one, and what the tooling costs, is stated in the written quotation; charges are tied to the design they were made for.

Can I approve a sample before bulk production?

Yes. The artwork and specification are approved first, then a physical sample of the chosen structure and fixing method; that sample becomes the reference for bulk production.

What is the MOQ?

It depends on the structure, the tooling and the size, so it is stated for your design in the written quotation rather than fixed by a list price.

What is the production lead time?

Timing is confirmed per order and depends on artwork approval, tooling, quantity and scheduling. It is stated in the quotation, and a production date is not a delivered-by promise.

Can you arrange shipping to my country?

Yes — express, air or sea freight, or your nominated forwarder. The method is confirmed against the destination and quantity. Product cost, freight, duties and taxes are agreed separately.

Start your quote

Send your artwork and project details

Tell us the finished size, the surface the patch goes on and how it is fixed. Artwork is reviewed at its intended size before we quote, because thickness, relief and color areas decide what the construction can hold — a clear photo or sketch is enough to start.

To prepare your quotation

  • Artwork file: vector (AI, EPS, SVG) or a clean high-resolution image
  • Finished width and height, or the maximum area available on the item
  • Structure: flat, raised or layered, and which elements should stand out
  • Quantity per design, and the number of designs in the project
  • Where the patch is fixed and how — sewn, hook and loop or adhesive
  • Color references, and any physical sample you are matching
  • Destination country and the date you are working towards

A sketch, artwork or reference photo is enough to start. We confirm what is needed for a production-ready file.

PDF, JPG, PNG, AI, EPS, DWG or STEP. Maximum file size: 20 MB.

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