Choosing the Best Material for Custom embroidered Patches A Quick Guide

Types of Material

There are different types of fabrics being used in embroidery industry for patches, but common options include.

  • Cotton
  • Polyester
  • Twill ( cotton-poly blend)
  • Felt
  • Leather (for high End usage)

Purpose of Material:

Purpose: The fabric/ Twill / Felt provides the foundation for the embroidered design and can influence the patch’s durability and flexibility.


Natural Feel:

Cotton is a natural fiber known for its soft and breathable characteristics. Cotton patches offer a comfortable feel against the skin, making them suitable for applications where comfort is a priority.


Cotton patches typically have a matte finish, providing a classic and timeless look. Cotton takes color well, offering a rich and vibrant appearance to the embroidered design.


Cotton is absorbent, which can be advantageous in situations where moisture management is crucial. This feature makes cotton patches suitable for items that may come in contact with sweat.


Natural Feel: Cotton provides a soft and natural feel against the skin.

Matte Finish: Cotton patches typically have a classic matte finish.

Breathability: Cotton is breathable, making it comfortable for various applications.


Absorbency: Cotton is absorbent, which may not be ideal for patches in moist or wet conditions.

Wrinkling: Cotton can wrinkle more easily compared to synthetic fabrics.


Durability and Color Retention:

Polyester is a synthetic material known for its durability and excellent color retention properties. Polyester patches can withstand frequent use and washing without losing their shape or vibrancy.

Quick Drying:

Polyester dries quickly, making it suitable for patches exposed to moisture. This feature is advantageous for outdoor or high-activity applications.


Polyester is a versatile material that can mimic the look and feel of other fabrics. It offers a glossy finish and maintains its brightness over time, making it suitable for designs with intricate color details.


Durability: Polyester is highly durable and resistant to wrinkles and shrinking.

Color Retention: Excellent color retention, maintaining vibrancy over time.

Quick Drying: Polyester dries quickly, suitable for patches exposed to moisture.


Less Natural Feel: Polyester lacks the natural feel of cotton.

Environmental Impact: Being synthetic, polyester is not biodegradable.

Twill (cotton-poly blend)

Durable Structure:

Twill’s diagonal weave imparts a robust structure to the fabric, making it an excellent choice for patches that need to withstand regular use and handling.

Textured Appearance:

The diagonal lines in twill fabric add a textured and dynamic quality to embroidered designs. This texture enhances the visual interest of the patch, making it stand out.

Versatility in Design:

Twill provides a versatile canvas for embroidery. Its weave allows for intricate detailing, making it suitable for patches with complex and elaborate designs.


Textured Appearance: Diagonal weave pattern provides a textured surface.

Durability: Twill is robust, making it suitable for patches exposed to regular wear.

Versatility: Accommodates various embroidery techniques and thread types.


Weight: Depending on the weight, twill may be heavier than other materials.

Overall, poly-cotton blends offer a good balance of durability, wrinkle resistance, and affordability. However, their lower breathability and absorbency compared to pure cotton should be considered depending on your needs and preferences. Weighing the pros and cons can help you decide if a poly-cotton blend is the right choice for you.


Soft Texture:

Felt is known for its soft and fuzzy texture, providing a different tactile experience compared to other patch materials. This softness adds a comforting and approachable quality to the patches.

Warm Appearance:

Felt has a warm and cozy appearance, making it suitable for designs that aim to convey a friendly or nostalgic feel. It works particularly well for patches with a vintage or handmade aesthetic.

Ease of Cutting and Sewing:

Felt is easy to cut and sew, making it a favorite for DIY projects. Its flexibility allows for intricate cuts and detailed designs, making it an ideal choice for patches with elaborate shapes.

Versatility in Design:

Felt’s smooth and even surface is conducive to various embroidery techniques. It accommodates both simple and complex designs, allowing for creativity and customization.


Soft Texture: Felt has a soft and fuzzy texture, adding warmth to designs.

DIY-Friendly: Easy to cut and sew, making it ideal for DIY projects.

Unique Aesthetic: Offers a distinctive and handmade aesthetic.


Durability: May not be as durable as synthetic fabrics like polyester.

Moisture Sensitivity: Felt is more prone to moisture absorption.


Smooth Feel:

Leather is all about that smooth, luxurious touch that adds a dash of class to anything it touches. Leather patches bring a sense of sophistication and style to your gear or outfit.

Look: Leather patches boast a rich, elegant appearance that just screams quality. With their glossy finish and natural texture, they give off an authentic vibe that’s hard to beat.

Sturdiness: Leather doesn’t mess around when it comes to durability. It can handle whatever life throws at it, making leather patches a solid choice for items that need to stand the test of time.


Smooth Feel: Leather patches offer a touch of luxury and elevate your style game.

Sleek Appearance: Leather patches exude richness and class, making a statement wherever they’re seen.

Built to Last: Leather is tough stuff, ensuring your patches stay looking sharp for the long haul.


Maintenance: Leather needs a little TLC to keep it in top shape. Price: Genuine leather can hit your wallet a bit harder than synthetic options.

Ultimately, the best choice depends on your specific preferences, the intended use of the patches, and the desired aesthetic. Whether you lean towards the natural feel of cotton, the durability of polyester, the warmth of felt, or the textured appeal of twill, understanding the unique qualities of each fabric will help you create embroidery patches that meet both your creative vision and practical needs.