Patch quotes in the UK mostly follow two numbers: size in inches and quantity. Thread, PVC, and chenille all get cheaper per piece as the run grows. Our standard minimum is 5 patches per design because setup, digitizing, and mockup time are similar whether we run 5 or 500. This guide helps you size the order without overbuying.
Common sizes and where they go
| Size (longest side) | Typical placement | Notes |
|---|---|---|
| 2–2.5 in | Caps, chest marks, kids’ merch | Simple logos only on embroidery |
| 3–3.5 in | Jackets, bags, team marks | The all-purpose size |
| 4–5 in | Backs, large logos, chenille letters | Needs bold shapes |
| Custom shape | Priced on longest side | Complex outlines cost more |
Why 5 pieces is the usual MOQ
Machines need a stitch file, a PVC mold path, or a chenille setup. Proofing spelling and color takes the same care at 5 pieces as at 500. Five lets a team, shop, or launch cover the roster without leftover pallets. Custom manufacturing starts at 5 pieces per design.
Quantity breaks (the idea, not a price list)
Unit price drops as you pass 250, 500, and 1,000+ because setup is amortized. Doubling size does not double price in a straight line, but it does add fill. A 5-inch 100% coverage embroidered patch is a different job than a 2-inch outline logo. We quote from your file rather than a public grid so you are not paying for coverage you do not need.
What else affects cost
- Stitch density or PVC complexity
- Number of colors
- Unique shapes and cut paths
- Backing (Velcro vs sew-on vs iron-on)
- Rush production
Using the budget slider
Have a number in mind? Our quote form includes an optional budget slider from £60 to £10,000+ so we can recommend size, type, and quantity that fit. Every quote still includes a free digital mockup before you spend on production. That is how you avoid buying 500 pieces of the wrong size.
A simple planning example
A 16-player travel team plus coaches might order 25 cap patches at ~2.5 inches (extras for fans) and a separate 25-count bag patch at 3 inches if those are different designs. That is two lines, two mockups, two minimums—not one blob of “50 mixed patches.” Planning it that way keeps delivery dates honest.