Custom embroidered patches cost anywhere from $0.44 to $42.60 per patch, depending on size, quantity, and embroidery coverage.

At the low end, a 1-inch patch with 50 percent coverage ordered at 2,000 pieces runs about $0.44 each. At the high end, a 7-inch patch with 100 percent coverage ordered as a 10-piece proof run runs about $42.60 each.

Every order at Patch Makers USA ships with no minimum order quantity, free digitizing, and free shipping, and a full quote is returned within one business day based on your actual artwork rather than a generic average.

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Quick Answer: 3 Inch Embroidered Patch Pricing

For a custom embroidered patch price at the most commonly ordered size, here is the per-patch rate across quantity and embroidery coverage.

The 75% row is simply the halfway figure between the 50% and 100% figures that are published. You will have to use your own judgment regarding the specific embroidered patch cost per patch based on your design.

Calculating Patch Cost & Sizing

Size, quantity, and coverage all move the price at once, which makes a static table hard to scan for anything outside the 3-inch benchmark. The patch pricing calculator found on our pricing page is scoped to embroidered orders and returns a live per-patch rate as you adjust size, quantity, coverage, and backing, so you can model your order before requesting a formal quote.

What Determines Embroidered Patch Price

Custom patch pricing is not a flat rate. It is built from a handful of variables that each move the per-patch cost independently, and understanding them is the fastest way to bring a quote down without changing your design’s core identity.

Patch Size (1 Inch to 7 Inches)

Size is the single biggest driver of custom embroidered patches cost by size. A larger patch uses more twill backing, more thread, and more machine time, so price scales with surface area rather than with diameter alone. A 2-inch patch used for a hat or lapel sits at the cheapest end of the range.

A 4-inch patch commonly used on jackets and uniforms sits in the middle. Oversized back patches above 7 inches carry a significant premium because they require multiple embroidery passes and are quoted individually.

Quantity and Bulk Order Discounts

There is an upfront cost for embroidery that is distributed to each patch made, which makes the cost per patch decrease as more patches are purchased. Patch Makers USA does not have a minimum order quantity requirement, making it easy for individuals and groups to purchase their desired quantity.

The biggest reduction in custom embroidered patches price per piece occurs in the transition from the 20-piece range to the 300-piece range. This is the reason why consumers who intend to order again in the future will be better off ordering in just one batch.

Embroidery Coverage: 50% vs 75% vs 100%

Embroidery coverage is the variable most specific to embroidered patches, and it deserves the most attention when budgeting.

Embroidery coverage refers to how much of the patch surface is filled with thread versus left as exposed twill fabric framed by a merrowed border.

In the case of 50% coverage, the fabric will remain visible and is the least expensive of all the coverage styles because it entails the least amount of sewing passes.

In case of 100% coverage, the fabric will be fully covered by the stitches and will cost the most, as it will need the highest amount of sewing to cover the same space.

A 75% coverage style lies between the other two and is popular among many buyers. It provides almost full coverage without the high costs.

Moving a design from 100 percent down to 75 or 50 percent coverage is one of the most direct ways to lower how much do custom embroidered patches cost without shrinking the patch or simplifying the artwork.

Thread Colors

Every extra color that is added adds to the basic price because the embroidery machine will need to be stopped and another spool loaded in.

The majority of orders have 6 to 12 colors in the basic price with no extra charge. Therefore, reducing the number of colors used in the logo is an easy way to cut costs.

3D Puff Embroidery Upcharge

The price of 3D puff embroidery patches is higher than that of flat embroidery since the foam layer below the stitches creates elevation in parts of the design.

The foam fabric, additional stitches to ensure its stability, and the increased rate at which it takes to produce it are responsible for the added cost compared to the same design produced using flat embroidery techniques. Likewise, metallic thread and glow-in-the-dark thread carry a similar upcharge.

Backing Type

Backing options vary in cost within an embroidered order:

• Sew-on backing is usually the cheapest option and is included in the base price at most shops.
• Iron-on (heat-seal) backing adds a modest per-patch fee for the heat-activated adhesive layer.
• Adhesive peel-and-stick backing sits slightly above iron-on.
• Velcro (hook and loop) backing carries the largest premium of the common options, since it requires an additional material layer bonded to the back of the patch.

Border Style

A merrowed border, the classic overlocked stitched edge, is the standard and typically the cheapest option.

Hot-cut borders, where the edge is heat-sealed without the merrowed overlay, suit intricate cut-out shapes and carry a small premium.

Laser-cut borders offer the most precise edge for irregular or multi-part shapes and sit at the higher end of border pricing.

Full Embroidered Pricing Chart by Size

The 3-inch size has published rates across every quantity tier, shown below. For 2-inch, 4-inch, and 5-inch patches, the benchmark rate at 100 pieces is listed here.

Use the pricing calculator for a live rate at other quantities or see the full 13-size chart on the pricing page.

3 Inch Embroidered Patch

Benchmark Rate at 100 Pieces, By Size

Prices climb steadily with size because material and thread usage scale with surface area rather than with diameter. Sizes are available in half-inch increments from 1 inch up to 7 inches, and anything larger requires a custom quote.

Hidden Fees to Confirm Before You Order

A quoted per-patch price does not always reflect the full cost of an order. Patch Makers USA includes the following as standard, but it is worth confirming with any supplier before committing:

• Digitizing fee: The fee required for making the artwork into a digitized file readable by the machine. It is waived for the standard order at Patch Makers USA. For other orders, the digitizing fee will increase an otherwise small quote by $25-$75.
• Rush or expedited production: Standard delivery is in 7 to 10 business days. When reduced to 3-5 days, it increases the cost by 15% to 30%.
• Shipping: Shipping costs nothing for orders within the US at Patch Makers USA. Overseas manufacturers give a cheaper price without duties, broker charges, and delayed delivery periods.
• Oversized patches (7 inches and above): These need more than one pass on the machine and therefore are custom quoted.
• Revision fees: One to two mockup revisions are provided free. An additional charge will apply for extensive changes in the design after starting digitization.

Real Pricing Examples

Small Club Run: 100 patches, 3 inches, 75 percent coverage, sew-on backing. Published rate: $2.04 per patch.

Corporate Rollout: 500 patches, 3 inches, 100 percent coverage, standard turnaround. Published rate: $1.12 per patch.

Bulk Distribution Run: 2,000 patches, 3 inches, 50 percent coverage, sew-on backing. Published rate: $0.59 per patch.

These three examples use the same underlying pricing structure but land in very different places depending on quantity and coverage, which is why a direct quote against your own artwork is more reliable than a generic average.

Looking for a Different Patch Type?

This is true since embroidered patches continue to be the most sought after due to their cost effectiveness, longevity, and traditional texture.

For those interested in comparing embroidered patches to woven patches, PVC patches, or patches with photos printed on them, check out our comprehensive guide on custom patches.

How to Get the Best Price on Embroidered Patches

• Order in bulk tiers. Rounding up from 90 to 100 pieces, or from 450 to 500, can meaningfully lower the per-patch rate.
• Simplify the design. Fewer thread color changes reduce machine time and cost.
• Lower the coverage percentage. Dropping from 100 percent to 75 or 50 percent coverage is one of the most direct ways to reduce cost without shrinking the patch.
• Skip 3D puff if the budget is tight. Flat embroidery delivers a clean, durable result at a lower price point.
• Choose standard shapes. Circles, ovals, and standard rectangles avoid the extra die or laser-cut charges that irregular shapes can trigger.
• Compare quotes side by side. Pricing structures vary enough between suppliers that checking backing and digitizing fees alongside the headline rate is worth the extra few minutes.

Frequently Asked Questions

How much do 100 custom embroidered patches cost?

Patch costs vary according to their sizes, which can be between 1 inch and 7 inches, as well as their embroidery coverage, which can vary between 50, 75, and 100 percent. Cost per piece of 100% coverage falls between $1.39 and $7.45, while the cost for a whole batch of 100 pieces comes to about $139-$745.

Does the coverage percentage change the price?

Yes. The amount of embroidery coverage is one of the more direct factors that affect the custom embroidered patch pricing. A 100 percent coverage patch is going to cost more money than the exact same one but with 50 percent coverage, since it requires more thread and more passes through the machine. In the case of a 3-inch patch with 100 pieces, the price goes up from $1.87 to $2.23 per piece if you change the coverage from 50 to 100 percent.

Is there a minimum order for embroidered patches?

No. Patch Makers USA does not require a minimum order quantity, which means that artists or small groups can place orders for whatever quantity suits their needs. This means that smaller quantities will have higher rates per patch because the setup fee will be shared among fewer patches.