The short answer: a custom 2″ woven patch with two thread colors costs $78 for 50 ($1.56 each), $152 for 250 ($0.608 each) and $356 for 1,000 ($0.356 each). A 3″ patch is $83 for 50 and $467 for 1,000. Those are order totals with artwork setup included; shipping is added at checkout. Quantity moves the per-patch price far more than anything else, so the useful question is not "what does a patch cost" but "what does a patch cost at my quantity".
Every figure on this page comes from our published cost study, generated from the same pricing engine as the woven patch configurator. The study is a free CSV, so you can check the numbers or use them in your own budget.
Custom Patch Prices by Quantity
Woven patch, Merrow edge, sew-on backing, two thread colors:
| Quantity | 2″ patch | 3″ patch |
|---|---|---|
| 50 | $78 ($1.56 each) | $83 ($1.66 each) |
| 100 | $119 ($1.19 each) | $130 ($1.30 each) |
| 250 | $152 ($0.608 each) | $168 ($0.672 each) |
| 500 | $214 ($0.428 each) | $275 ($0.55 each) |
| 1,000 | $356 ($0.356 each) | $467 ($0.467 each) |
| 2,000 | $604 ($0.302 each) | $855 ($0.428 each) |
Above 2,000 pieces the per-patch price stays at its 2,000-piece level. For bulk runs, see wholesale patches.
What Sets the Price of a Custom Patch
1. Quantity
Each new design needs a weave file and a loom set up for its colors. That work costs the same for 50 patches as for 5,000, so on a small run it is most of what you pay for. Going from 50 to 250 cuts the price of a 2″ patch from $1.56 to $0.608 each. Going on to 1,000 brings it to $0.356. Most of the saving has happened by about 500 pieces, which is why a brand that will reorder anyway often saves more by ordering 250 or 500 at once than by splitting the run.
2. Size
On a small run, size matters less than people expect: 50 patches at 3″ cost $83 against $78 at 2″. The gap widens with quantity ($467 against $356 at 1,000), because more woven area means more loom time and thread for every extra piece. Large back patches, much above 4″, cost noticeably more per piece. The configurator shows the price for any size from 0.31″ to 7.87″ (8–200 mm).
3. Thread colors
Woven patches take up to twelve thread colors. Each extra color adds to the price, but far less than stitch count adds to an embroidered patch, and a detailed design costs no more to weave than a simple one with the same colors. Merging two near-identical shades in your artwork is the easiest saving.
4. Edge
A Merrow edge (the raised, overlocked border on classic badges) costs more than a hot-cut edge, which is sealed by heat and can follow any outline. For a custom shape, hot-cut is usually both the cheaper and the better choice.
5. Backing
Sew-on is the base price. Iron-on backing adds a small amount per patch, which grows with quantity. Hook-and-loop suits uniforms where the patch has to come off.
What Is Included, and What Is Not
- Included: artwork setup, a human review of your file within 24 hours, and a preview of the finished patch before you order.
- Not included: shipping, which is calculated at checkout. We ship to the USA and Canada only, with no import fees for US customers.
- No separate setup or digitizing fee. The configurator price is the price you pay for the patches.
When you compare quotes, compare the total for the same quantity, size and backing, including any setup fee and shipping. A low per-piece price with a setup charge on top can cost more on a 50 or 100-piece run.
Budgeting Patches per Product
For a merch or hat run, the patch is a per-item cost like the blank. At 1,000 pieces a 2″ woven patch adds $0.356 to each hat. At 100 pieces it adds $1.19. If the patch is iron-on and you also pay for application, add that separately. Sizing a patch for a cap panel or beanie cuff is covered in custom hat patches.
Are Woven Patches Cheaper than Embroidered Patches?
Usually, when the design has detail or covers most of the patch. Embroidery is priced by stitch count, so full coverage, small lettering and fine outlines all add cost. A woven patch is priced mainly by size and quantity, and it holds small text that embroidery fills in. A bold, simple mark with a lot of open background can be cheap either way. The differences in look, feel and durability are in woven vs embroidered patches. We also make embroidered patches on request, quoted per design.
The Cheapest Way to Order Custom Patches
- Order the quantity you will actually use over the next few months, not 50 at a time. The price per patch at 250 is well under half the price at 50.
- Use a hot-cut edge for custom shapes.
- Keep the thread colors to the ones the logo really needs.
- Choose the smallest size that still reads on the garment; 2–2.6″ suits most cap fronts.
- Reorder the same design: approved artwork is stored, so a reorder is one click and matches the first batch.
Check Your Design First
If you want to see your own design before a full run, a Woven Patch Proof Pack is five real patches of your design with a photo proof. To feel the material first, the $1 sample kit ships real production samples to the USA and Canada. When you are ready, upload your logo in the patch configurator and the price updates as you change size, edge, backing and quantity.
Frequently Asked Questions
How much do custom patches cost?
From our published cost study, a 2″ woven patch with two thread colors costs $78 for 50 ($1.56 each), $152 for 250 and $356 for 1,000 ($0.356 each). A 3″ patch is $0.467 each at 1,000. Artwork setup is included; shipping is added at checkout.
How much do 100 custom patches cost?
100 custom 2″ woven patches cost $119 ($1.19 each) with two thread colors, a Merrow edge and sew-on backing. The configurator prices your exact size, edge, backing and colors live before checkout.
What is the cheapest way to get custom patches?
Order the full quantity you need in one run, because setup is paid once per design and the price per patch falls steeply up to about 500 pieces. A hot-cut edge, fewer thread colors and the smallest size that still reads all lower the price further.
Is there a setup fee for custom patches?
No. Artwork setup and the artwork review are included in the price the configurator shows. Shipping is the only addition, calculated at checkout for the USA and Canada.
Are woven patches cheaper than embroidered patches?
Usually, when the design has detail or covers most of the patch. Embroidery is priced by stitch count, so coverage and fine detail add cost; a woven patch is priced mainly by size and quantity. Embroidered patches are made on request and quoted per design.
What is the minimum order for custom patches?
Standard runs start at 50 patches per design ($78 for 50 at 2″). To see your design first, a Woven Patch Proof Pack is five real patches with a photo proof for $40.
Do bigger patches cost more?
Yes, but less than you might expect on small runs. The gap grows with quantity: at 1,000 pieces a 2″ patch is $0.356 each and a 3″ patch $0.467 each. Back patches much above 4″ cost noticeably more per piece.