Frequently Asked Questions

An Embroidered Patch is a piece of artwork created thru an embroidery machine using materials such as cotton twill and different colour threads. It conveys a theme, event or logo that commemorates the users’ message.

Embroidered emblems and patches are a great way to put your design or insignia on a garment without applying the decoration directly to the garment. These emblems & patches are generally produced on a heavy twill fabric with a smooth texture.

In most cases a portion of the underlying twill becomes the background for the design, and a variety of thread colors make up the details of the design. There is a decorative stitch that overlays the edge of the twill fabric to make your custom embroidered emblem.

Embroidered emblems and custom patches are commonly produced for outerwear, clothing and accessories. They work great for uniforms, caps, jackets and golf shirts when you want maximum recognition and exposure. We use the highest quality fabrics and threads to make your embroidered emblems and patches.

What are the Benefits of Custom Embroidered Patches

Embroidered patches can benefit you in many ways.

* Option to be heat sealed or sewn on garments.

* Designed for industrial laundering.

* Gives opportunity to remove design at anytime without ruining the garment.

* Removable, allowing for reuse of garments.

* Multiple shapes and sizes.

* Can save as much as 30% over the cost of direct embroidery.

* Allows you the opportunity to have your design sewn without purchasing a garment.

* Durable in active environments such as industrial, healthcare and hospitality.

How are your Patches produced?

Once a digital mock-up is done our digitizers will create a DST file. DST is a file format which embroidery machines use to translate a design into an actual embroidered patch.

Digitizing is the indispensable foundation of any embroidered design. In essence, digitizing is the sophisticated process of converting text or a printed design into an embroidery format. The output of this conversion is a set of instructions that directs the embroidery machine to know what thread color to sew and where to place each stitch, culminating in a thread based mirror image of the original.

The factory will use the mockup as a guide for colors, special options and other instructions. They will feed the dst file to the embroidery machine and start with production.

Digitizing Considerations: Small elements such as tiny graphics or very small lettering may retain their detail in printing, however they do not always embroider well and may need to be either enlarged or removed completely from the design. For best embroidery results, avoid miniature graphics and text smaller than .25 inch. Refer to Patch Design Guideline Document for more technical informatin about designing for patches.

Fact: A sew-out is a replica of the finished design and is provided to customer for approval before proceeding with the actual embroidery.

Where do customers start if they want an embroidered Patch?

Customers start with an idea of how they want their patches to look. Customers provide us different resources to create a digital representation of their patch order.

Some customers provide:

• An idea only; notes and descriptions about their patch.

• A sketch or rough image of their patch.

• A set of pictures for references

• An actual picture of their existing patch

• An actual sample they send to our office to create 100% match

Whatever they provide, our Graphic Designers will create a digital mockup which will be sent to the customer for approval. This same mock-up will be used by our Digitizers, to create a DST file, and by the factory to produce the actual patch.

What are Butler Patch Features?

We offer up to 12 thread colors on each design. More colors are available for addional cost.

We use thick cotton twill as the base for embroidery (this material is similar to material used in caps/ baseball caps)

We offer special options for threads

We offer other materials for base

Who are your Customers?

Patches serve as a quick, easy way to visually identify our customers with any group, organization or event. By wearing a team logo, customers can feel being a part of the group no matter where they are. People will recognize them and connect them with something larger.

In General, Butler Patches caters to any customer who would like to have a visual identity of their group thru embroidered patches. Our regular customers include:

Military
Airsoft teams
Paintball Teams
Martial Arts Clubs
Companies and Organizations
Schools, High Schools, College and Universities
Event Organizers
Fire Department and EMS
Police Departments
Security Organizations
Boy Scouts and Girl Scouts
Soccer Teams, Foot ball teams and other sports teams

What is Percentage of Embroidery?

Our Patches are available in various Embroidery Percentages. We offer customers 3 choices:

1. 50% Embroidery – This means 50% or less of the patch surface area will be covered in embroidery. This method is ideal for Name patches (patches that display name or position of the user. E.g. “Trevor” or “President”). This is usually used for much simpler patches that displays words or numbers only.

2. 75% Embroidery – This means 75% or less of the patch surface area will be covered in embroidery. This is most widely used method for our patches. Unless specified by the customer, our Brand Specialists usually note a standard order with 75% Embroidery. 75% embroidered patches are sometimes good for a lot of detail. If there is a lot of detail and the size is not large embroidery on embroidery (100%) can cause difficulty in the embroidery.

3. 100% Embroidery - This method will cover 100% of the patch surface area. No cotton twill will be exposed in the patch. Some customers prefer this because it makes the patch look more beautiful and luxurious; however this method is not suitable for all patch designs.

What are the Available Patch Shapes?

We have two standard shapes:

• Circle or round

• Square

Non-traditional shapes are called “Cut to shape”. Any shape other than circle and square are labelled as “cut to shape”

What's the standard Patch Size?

Patch sizes can start from 1 inch to 12 inches (sometimes even larger). The proper size for a custom patch is determined by its intended use.

For caps and hats, most people prefer patches from 1” to 3”

Shoulder patches and front jacket patches are commonly 3.5” to 5” inches tall

Back patches range from 10” to 17” sizes

To measure a patch you should add the height and the width then divide the sum by 2

(H+W)/2 = Patch size

What is your minimum order requirement?

Butler Custom Woven Labels will entertain orders as small as 10 pcs. We can also accomodate large quantity orders and will deliver your product on time with the lowest price available in the market today.

Other Custom Products