Frequently Asked Questions

Upload your artwork through our website or email it to mail@usabadge.com. Our team will review your design within 24 hours and send you a free digital mockup showing exactly how your patch will look. You don’t need production-ready files — a photo, sketch, or even a napkin drawing is enough for us to get started. We’ll handle the rest.

Absolutely. Send us your design and tell us where the patch will be used (uniforms, hats, jackets, merchandise, etc.) and we’ll recommend the best patch type based on your design’s detail, size, and intended use. Here’s a quick guide:

Bold logos and text: Embroidered patches — classic raised stitching, the most popular choice.

Fine detail and small text: Woven patches — smooth, flat, high-definition finish.

Gradients or photos: Printed patches — full-color dye sublimation, unlimited colors.

Outdoor or tactical gear: PVC patches — waterproof, rugged, 3D molded rubber.

Athletic or performance wear: Silicone patches — soft, flexible, stretches with the fabric.

Luxury or ceremonial: Bullion patches — 100% hand-embroidered with gold and silver wire.

If you’re still unsure, we’ll send you mockups of more than one option so you can compare before committing.

We accept virtually any format: AI, EPS, PDF, SVG, PNG, JPG, PSD, CDR, and even photographs or hand-drawn sketches. Vector files (AI, EPS, SVG) give the best results, but if all you have is a photo or a low-resolution image, our digitizing team will redraw it to production quality at no extra charge.

No. Vector files are ideal, but we work with whatever you have. Our in-house digitizing team has decades of experience converting images, logos, sketches, and even descriptions into production-ready artwork. If your file needs redrawing, we do it for free as part of the process.

Pricing depends on the patch type, size, quantity, and complexity. Most of our products have a live price calculator on the product page — enter your size and quantity and you’ll see the price per piece instantly. For products marked “Quote Only” (chenille, bullion, TPU, metaprint), send us your design and we’ll return a quote within 24 hours. There are no hidden fees. The price you see includes your design setup, digitizing, and free mockup revisions.

Yes, minimums vary by product type:

10 pieces: Bullion patches

25 pieces: Embroidered patches, 3D puff patches, printed patches, subli-stitch patches, embroidered keyrings, printed keyrings

50 pieces: Chenille patches

100 pieces: Woven patches, PVC patches, silicone patches, raised silicone transfers, TPU patches, metaprint patches, woven labels, woven keyrings, PVC keyrings, all enamel pins

Every order goes through two approval stages before full production begins:

Step 1 — Digital Mockup: We create a detailed digital preview of your patch. You review it and request unlimited revisions until you’re completely happy. No charge for revisions.

Step 2 — Production Sample: We produce a real sample and send you a clear photograph for approval. You see exactly how your patch looks in thread, PVC, or whatever material you’ve chosen — before we run full production.

We do not begin full production until you’ve approved both steps. No guesswork, no surprises.

Yes — that’s exactly what our production sample step is for. After you approve the digital mockup, we manufacture one real sample and photograph it for you. You review the photo and either approve it or request changes.

Yes. When you approve your digital mockup, you can choose between a free digital sample (a clear, high-resolution photograph) or having the physical sample posted to you. We ship physical samples anywhere in the US and Canada via standard post for a flat fee of $11.

Please note: Because this uses standard mail (not overnight or expedited shipping), requesting a physical sample typically adds about 8–10 business days to your overall timeline. The $11 postage fee is non-refundable.

Yes. We revise your digital mockup as many times as needed until you’re 100% satisfied. There is no cap on revisions and no extra charge. We’d rather spend time getting it right than rush something that doesn’t meet your expectations.

If the production sample doesn’t match the approved mockup, we’ll redo it at no charge. If you’d like changes to the design after seeing the sample, we’ll update the mockup, get your approval, and produce a new sample. We don’t proceed to full production until you’re fully satisfied.

Tell us your deadline when you place your order and we’ll be honest about whether we can meet it. Production times vary by patch type:

7–14 business days: Embroidered patches, 3D puff patches, printed patches, subli-stitch patches

14–21 business days: Woven patches, PVC patches, silicone patches, woven labels, keyrings, enamel pins

2–3 weeks: Raised silicone transfers, TPU patches, metaprint patches

Up to 5 weeks: Bullion patches (100% hand-embroidered)

These timelines start after final approval of your production sample. Add 1–3 business days for the mockup stage and 3–5 business days for sample production.

If you have a tight deadline, please get in touch with us before placing your order so we can assess if we can meet your date. In many cases, we are able to expedite your order without any additional surcharge. However, depending on current production queue volumes and the specific materials required, there may sometimes be a rush surcharge of up to 25%.

Because custom manufacturing is a batch business, our first priority is feasibility. While we keep an extensive stock of raw materials, we will not take on a rush order unless we are 100% confident we can make it happen for you on time.

A typical order timeline looks like this:

Day 1–2: You submit your artwork. We send a digital mockup within 24 hours.

Day 2–5: Mockup revisions (depends how quickly you respond).

Day 5–10: Production sample manufactured and photographed for your approval.

Day 10 onwards: Full production begins after your sample approval.

Total time from first contact to delivery is typically 2–4 weeks for most patch types, depending on the product and your approval speed. Bullion patches take longer due to handcrafting (up to 5 weeks for production alone).

Size depends on where the patch will be placed and how much detail your design has. Here are common sizes as a starting point:

2″–3″ (50–75mm): Hat patches, small chest logos, sleeve badges

3″–4″ (75–100mm): Standard uniform patches, jacket backs, most common size

If your design has fine text or intricate detail, going too small will lose clarity. We’ll advise you during the mockup stage if your chosen size won’t do justice to the design, and suggest alternatives.

Maximum sizes vary significantly depending on the manufacturing process and material you choose:

Embroidered & Printed Patches: Up to 20 inches

Woven Patches: Up to 18 inches

Raised Silicone Transfers: Up to 12 inches

PVC, Silicone & Metaprint Patches: Up to 6 inches

TPU Patches: Up to 5 inches

Metal Pins: Up to 3 inches

For large-format items like motorcycle club back patches, contact us to discuss the exact dimensions and feasibility for your specific artwork.

Start with the minimum order for your chosen patch type to test the quality and design. Once you’re happy, you can reorder any quantity. Keep in mind that the price per piece drops significantly at higher quantities — check the price calculator on the product page to see the volume breaks.

Because each colorway requires its own machine setup, material mixing, and thread change, each color variation is treated as a completely separate order. Each variation must meet the minimum order quantity for that product type on its own. For example, if the minimum is 25 pieces and you want a black background version and a white background version, you must order 25 of the black and 25 of the white. Send us all the variations together and we’ll quote the full order at once.

Yes. We work with Pantone Matching System (PMS) colors to ensure precise color reproduction. If you provide your Pantone references, we’ll match them exactly. If you don’t have Pantone codes, send us a sample or reference image and we’ll identify the closest match. For embroidered and woven patches, we select from our extensive thread library. For PVC and silicone, we custom-mix the material to your Pantone specification.

We offer five standard backing types for most patch products:

Iron-on (heat-seal): Adhesive backing activated by heat. Press onto fabric with a heat press or iron.

Velcro (hook-and-loop): Attach and remove patches easily. Great for tactical gear, interchangeable uniforms, and bags.

Sew-on: No adhesive — sewn directly onto the garment for a permanent, traditional finish.

Peel-and-stick (self-adhesive): Temporary adhesive for short-term use, displays, or positioning before sewing.

Heat-applied: Professional heat-press application for a flat, seamless bond. Common for sportswear and performance fabrics.

Not sure which backing suits your use? Tell us what the patch is going on and we’ll recommend the best option.

Two standard border types are available:

Embroidered (satin) border: Clean, sharp edges with a stitched finish. Ideal for detailed or custom-shaped designs. The most popular choice for a modern, premium look.

Merrowed (overlocked) border: A raised, wrapped-thread edge that gives a classic, traditional patch appearance. Standard for military, scout, and sports patches.

Our team will recommend the best border type based on your patch shape and design during the mockup stage.

Choose your product, enter your size and quantity on the product page, upload your artwork, and submit your order. We’ll send you a digital mockup within 24 hours. Once you approve the mockup, you choose your payment option and payment method, and we begin production. No payment is taken until you’ve seen and approved your mockup.

We accept all major credit and debit cards (Visa, Mastercard, American Express), which are processed securely through Stripe. For customers who prefer it, we also accept payment via standard bank transfer (BACS/wire).

Because everything we produce is custom-manufactured to order, standard orders require payment before production begins. Credit accounts are exceptionally rare and are strictly reserved for corporate partners who have maintained a consistent track record of monthly transactions with us over several years.

Yes. When you approve your mockup, you have three payment options:

Pay in Full: Pay the complete order amount upfront. Production sample is included at no extra charge.

Production Sample (digital): Pay only the sample fee now. We produce a sample and send you a photograph. Pay the remaining balance after you approve the sample.

Production Sample (posted): Pay the sample fee plus a postage charge. We post the physical sample to you. Pay the remaining balance after approval.

The sample fee is deducted from your total order cost — you’re not paying extra, just splitting the payment into two stages.

Most patch types are delivered within 10–21 business days from final mockup approval, depending on the product:

Fastest (9–14 days): Embroidered, 3D puff, printed, subli-stitch patches

Standard (14–21 days): Woven, PVC, silicone, enamel pins, keyrings, woven labels

Specialty (3–5 weeks): TPU, metaprint, raised silicone transfers, bullion

These are business days and do not include weekends or public holidays.

We ship via FedEx to all 50 states. Standard delivery across the contiguous 48 states is completely included in your order price. Deliveries to Alaska and Hawaii do incur an additional shipping surcharge—typically ranging from $25 to $40, depending on the exact weight and volume of your patches.

Our standard shipments are dedicated strictly to the United States and Canada. However, if you need an order shipped internationally, please contact us before placing your order. Because we utilize a global manufacturing network—including a production facility in the UK—we can often arrange to ship your patches directly from the factory to your international location. Just let us know where you need them, and we will work out a custom shipping quote and logistics plan for you.

We strictly commit to the production timeline quoted when you place your order, and we guarantee that your order will be dispatched within that window. However, because the final delivery is handled by third-party carriers like FedEx, we cannot offer a money-back guarantee for transit delays caused by the courier.

That being said, courier delays are very rare. If your project is highly time-sensitive and you require fully insured, specialized delivery logistics, please let us know before ordering. We can arrange premium, fully insured courier options for an additional fee to give you complete peace of mind.

No. We handle all sourcing and logistics, so you won’t face hidden customs charges, unexpected import duties, or surprise fees on delivery. The price you’re quoted is the price you pay.

Yes. Once your order is dispatched, we’ll send you a tracking number by email so you can follow your delivery in real time.

It is very simple. Once your initial order has been fully delivered, you can log in to your account dashboard, view your past orders, and click “Reorder”. We securely keep your artwork, digitizing files, and specifications on file for five years. Because the setup is already complete, your repeat order skips the mockup stage and goes straight to production. Same quality, faster turnaround.

Yes. You can order any quantity above the minimum for that product type. Your per-piece price may change based on the new quantity — higher quantities mean lower prices. The design, digitizing, and setup are already done, so there’s no additional setup cost.

We securely store your artwork, digitizing files, and order specifications for five years after your last order. Whether you need a repeat run next month or in a few years, your files will be ready to go straight to production, ensuring perfect consistency with no additional setup required.

Embroidered patches use thread stitched on top of a fabric base, creating a raised, textured surface. They’re bold, durable, and the most popular choice for logos and text. Woven patches use thread woven directly into the fabric, creating a smooth, flat finish with much higher detail. Woven is better for fine lines, small text, and intricate artwork. If your design has large bold elements, go embroidered. If it has fine detail or text under 5mm, go woven.

PVC is thick, rigid, and rugged — built for tactical gear, backpacks, heavy jackets, and hats. Silicone is soft, flexible, and lightweight — built for athletic wear, compression gear, swimwear, and anything that needs to stretch. A quick rule: if the patch goes on something heavy or structured, choose PVC. If it goes against skin or on performance fabric, choose silicone.

3D puff uses foam underneath the stitching to create a raised, three-dimensional effect. It looks fantastic on bold letters, thick outlines, and chunky logos. However, it’s not suitable for fine details or thin lines — the thread needs width to wrap cleanly around the foam. We call this the Chopstick vs Toothpick rule: if the line is as thick as a chopstick, 3D puff will look great. If it’s as thin as a toothpick, it won’t hold. If any part of your design is too fine for 3D, we’ll reach out proactively and recommend a flat-stitch alternative for those elements.

TPU (Thermoplastic Polyurethane) is a high-tech material that acts as a bridge between rubber and plastic. TPU patches are structured, low-profile, and razor-sharp—holding sharper angles than silicone while feeling lighter and more architectural than PVC. They are the premium choice for modern tech-wear, high-end outerwear, and sleek streetwear.

Metaprint is a TPU base with a high-end metallic coating that looks like brushed or polished metal — think of a luxury car emblem. Compared to real metal badges: same premium look, but lightweight, flexible, and heat-press ready. No rivets, no garment damage, no tarnishing. Compared to metallic foil or heat-transfer vinyl (HTV): not even close. Foil and HTV are flat, thin plastics that peel, crack, and fade. Metaprint is a molded 3D badge with structure, depth, and a genuine metallic finish.

These premium items require specific design parameters to manufacture correctly. For instance, Metaprint and TPU are physically 3D molded, meaning they require solid colors and cannot use gradients or shading. Chenille uses a tufted pile that cannot handle fine text. Rather than letting you check out with a design that won’t work, we review every request manually. If your artwork is suitable, we provide a custom quote within 24 hours.

Subli-stitch is a hybrid option. It combines the unlimited color freedom and photo-realism of dye-sublimation printing for the base of the patch, with traditional embroidered stitching applied over the top for key elements like the border and text. It gives you the best of both worlds: perfect gradients and colors alongside a premium, tactile stitched feel.

Custom woven labels are designed to be sewn into the neckline or hem of a garment. They are the finishing touch that transforms a generic, off-the-shelf blank t-shirt or hoodie into a retail-ready product. They offer high-definition text, exact brand colors, and are incredibly soft against the skin.

Soft enamel pins have raised metal borders with color sitting in the recessed areas, giving a textured, 3D feel. They’re the most popular and cost-effective option. Hard enamel pins are polished completely flat — the enamel is sanded flush with the metal, creating a smooth, jewelry-quality finish that’s more scratch-resistant. Quick guide: want classic textured pins? Soft enamel. Want them to feel like a luxury watch? Hard enamel.

While there are typical starting points for iron-on backing, the exact temperature and press time depend entirely on the composition of the fabric you are applying it to. A temperature that works perfectly for heavy cotton might melt a lightweight polyester athletic shirt.

Because fabric composition varies so drastically, we strongly urge customers to always order a couple of extra badges to use for testing. You should always test your heat press settings on a scrap piece of the exact same fabric before applying the patch to your final garment. Use a protective cover sheet (like Teflon or parchment paper) and adjust your temperature and time based on how the fabric responds. If you are completely new to heat pressing, let us know and we can send you a sample pack to practice with before you apply your final custom order.

To keep your patches looking their best:

Turn the garment inside out before washing.

Wash in cold or warm water (not hot).

Avoid bleach and harsh detergents.

Tumble dry on low heat or hang dry.

Do not iron directly over the patch — place a cloth between the iron and the patch.

Embroidered and woven patches are extremely durable and will outlast most garments. PVC and silicone patches are waterproof and need no special care.

Because of our strict two-step approval process, quality issues are incredibly rare. Before we ever begin full production, you must explicitly approve a high-resolution photograph of the actual physical sample. What you approve in that photograph is exactly what is produced and delivered.

Please be aware that colors can appear differently depending on the phone or computer screen you are using to view the mockup or photograph. If you are ever unsure about a detail, texture, or color, you can request the physical sample to be mailed to you for review before you give final approval.

Once final approval is given, production begins immediately and no further changes can be made. Because everything is custom-manufactured based on your approval, we do not accept standard returns, and issues like “the color looks different than my monitor” do not qualify as defects. However, if there is a genuine physical manufacturing error, please contact us within 7 days of delivery and we will reproduce the defective items at no charge.

Cancellation depends on where your order is in the process:

Before mockup approval: Cancel at any time, no charge.

After mockup approval but before production sample: Cancel at any time, no charge.

After sample payment: The sample fee is non-refundable (unless the issue was on our end), but no further charges apply.

After full production starts: Orders cannot be cancelled once production has begun.

If you need to make changes rather than cancel, contact us as early as possible and we’ll do our best to accommodate.

Yes. Our pricing is quantity-based — the more you order, the lower the price per piece. You can see exact volume breaks on each product’s price calculator. For very large orders (10,000+ pieces), contact us directly for a custom quote.

Yes. We proudly support schools, sports teams, military units, first responders, and registered non-profits across the United States. If you fall into one of these categories, contact us via email or live chat before checking out and we will provide you with a 10% discount. We can either issue you a promo code to use at checkout, or we can simply apply the discount to your final balance invoice when you approve your production sample.

Absolutely. Many of our customers are brands, merch companies, and retailers who resell under their own name. We offer woven labels for garment branding, and your patches come with no USA Badge branding — they’re your product. We’re your manufacturing partner, not your competitor.

Yes, and it’s one of the easiest add-ons. If you’re already ordering patches, a matching keyring or enamel pin uses the same artwork. We’ll set up both products from your single design file and produce them in parallel.

USA Badge is a custom patch and badge manufacturer serving businesses, teams, and organizations across the United States. We’re operated by Digitizing LLC. Our production is powered by a global network of specialist manufacturers — each selected for their expertise in specific patch types — backed by decades of combined experience in embroidery digitizing and patch manufacturing.

Our production is powered by a global network of specialized manufacturers, anchored by our main production unit in the UK. Because we offer such a wide, expanding variety of premium products—from hand-embroidered bullion to 3D molded PVC and Metaprint—no single factory can be an expert in everything. Instead, we use vetted specialist partners for each specific material type. We manage the quality control, approve every sample, and handle the full logistics chain. You deal directly with our team, and we ensure you get the absolute best quality across every patch type.

Our location in Edison, New Jersey, serves strictly as our corporate and administrative office. While this facility handles the dispatch of our physical samples, we operate as a nationwide e-commerce provider rather than a retail storefront. Therefore, we do not have a showroom and do not accommodate walk-ins or in-person meetings. We are, however, always happy to mail physical samples directly to you so you can review our quality and materials firsthand. For project discussions, our team is highly responsive and always available via email or live chat to review your artwork and guide you through the process.

You can reach us by:

Email: mail@usabadge.com

Phone: +1 (401) 655-1153

Website: Use the contact form at usabadge.com/contact

We aim to respond to all inquiries within 24 hours during business days.

Embroidery coverage refers to how much of the patch surface is covered in stitching versus the base fabric showing through. 100% coverage means the entire surface is stitched — no fabric visible. 75% coverage means some background fabric shows through. Higher coverage gives a denser, more premium feel but uses more thread. We’ll recommend the right coverage for your design during the mockup stage.

Digitizing is the process of converting your artwork into a stitch file that embroidery machines can read. It’s a skilled process — not just tracing, but deciding stitch direction, density, underlay, and sequence to produce the best result. Digitizing is included free with every embroidered patch order. You don’t pay separately for it.

We carry an extensive range of thread colors, including standard Pantone-matched shades and metallic threads (gold, silver, copper). If you provide a Pantone reference, we’ll match it. For embroidered patches, our standard thread library covers over 400 colors.

We produce patches in any shape — circles, rectangles, shields, stars, state outlines, custom die-cut shapes matching your logo silhouette, or any other form. Custom shapes are standard and there’s no extra charge for non-standard outlines.

END OF FAQ — FINAL APPROVED

49 questions • 12 categories • All business decisions confirmed

Ready to paste into admin panel.