25–200mm · Standard & Bespoke Die-Cut Shapes
PVC Patch Sizes and Custom Shapes
Custom PVC patches are moulded rubber badges produced between 25mm and 200mm, in round, square, rectangular, oval, shield and bespoke die-cut shapes. PVC patch size is quoted as the average of width and height, the convention UK suppliers measure against. Custom die-cut shapes follow the outline of your artwork at no extra tooling cost, and every size and shape is available with no minimum order.
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Available formats
What Sizes and Shapes Are Custom PVC Patches Made In?
Custom PVC patches are made in any two-dimensional outline between 25mm and 200mm. Standard shapes include round, square, rectangular, oval and shield. Custom die-cut shapes reproduce an irregular profile — a shield with a banner, a mascot silhouette, a multi-part crest — because the metal mould is engraved to match the artwork exactly. Shape places no limit on size, and size places no limit on shape: a 40mm circle and a 200mm die-cut back panel follow the same production route.
Measurement convention
How PVC Patch Size Is Measured
PVC patch size equals the average of the width and the height. A patch measuring 80mm wide by 60mm tall is quoted as a 70mm patch. This measurement convention returns a single figure for irregular and die-cut shapes, where width and height differ. Size therefore describes the overall footprint of the patch, not the length of any single edge. UK patch suppliers quote against this average, so a quoted dimension stays directly comparable between designs.
Width
80mm wide
Measure the full horizontal footprint of the finished design.
Height
60mm tall
Measure the full vertical footprint of the finished design.
Quoted size
70mm patch
Average the width and height to return the single quoted size.
Minimum to maximum
PVC Patch Size Range — Minimum to Maximum
Custom PVC patches range from a 25mm minimum to a 200mm maximum. Small patches below 40mm suit lapels, caps and chest badges, where panel space is limited. Large patches above 150mm suit jacket backs and club colours, where the design carries across a full panel. Size affects legibility directly: a smaller footprint holds less fine detail, while a larger footprint reproduces intricate crests and lettering cleanly.
Standard PVC Patch Sizes by Application
The table below maps common PVC patch sizes to their typical application and suitable relief.
| Size (avg. of width and height) | Typical application | Suitable relief |
|---|---|---|
| 40–50mm | Cap fronts, chest badges, lapels | 2D or 3D |
| 50–70mm | Polo and shirt chests, small morale patches | 2D or 3D |
| 75–100mm | Sleeves, jacket chests, bags | 2D or 3D |
| 100–150mm | Large morale patches, equipment panels | 2D or 3D |
| 150–200mm | Jacket back patches, club colours | 2D or 3D |
Five standard outlines
Standard PVC Patch Shapes
PVC patches are supplied in five standard shapes, and each shape suits a different design.
- Round patches reproduce circular crests, unit badges and roundels.
- Square patches frame typographic logos and geometric marks.
- Rectangular patches carry name tapes, banners and horizontal wordmarks.
- Oval patches suit portrait crests and elongated emblems.
- Shield patches match military, cadet and club insignia.
Standard shapes require no bespoke outline work, yet each one is still cut to your exact dimensions. A standard shape and a custom shape cost the same, because both need a mould engraved to the design.
Bespoke profile
Custom Die-Cut Shapes
Custom die-cut shapes follow the exact outline of your artwork. A die-cut PVC patch carries no surrounding border, so the moulded edge traces the design itself — a dragon silhouette, a hexagon, a lettering-only wordmark. Die-cut shaping carries no additional tooling cost, because every PVC patch requires a bespoke mould regardless of profile. Complex outlines, internal cut-outs and multi-part shapes all reproduce with a clean, sealed edge. The custom die-cut shapes page explains the die-cutting process and edge finish in full.
Legibility limits
How Patch Size Affects Detail and Text
Patch size sets the smallest detail a mould can hold. A 2D PVC patch reproduces text down to a 5mm minimum height, and a 3D PVC patch reproduces text down to a 6mm minimum height. Below these thresholds, thin strokes merge and small letter counters fill in. Larger patches carry finer lines, tighter lettering and more colours within the same footprint. Design a small patch around a bold, simplified mark rather than dense detail. The minimum text size for PVC patches page sets out the legibility limits for each relief type.
2D relief
5mm minimum text height
Flat-topped relief holds smaller lettering before strokes begin to merge.
3D relief
6mm minimum text height
Sculpted relief needs slightly more space around small letterforms.
Size by application
Choosing the Right Size for Your Patch
Application decides the right PVC patch size. Match the footprint to the garment or piece of gear, then confirm the relief and backing.
40–70mm
Cap, Hat and Chest Patches (40–70mm)
Cap and chest patches measure 40mm to 70mm. A cap front holds a compact badge, so a 3D relief lifts a small logo without crowding the panel. Chest patches on polos and softshells sit at a similar scale. The cap and hat patches page covers headwear-specific sizing.
70–100mm
Sleeve and Pocket Patches (70–100mm)
Sleeve and pocket patches measure 70mm to 100mm. This mid-range footprint suits morale patches, sleeve badges and bag panels, and it pairs well with hook-and-loop backing for quick swapping between garments.
Up to 200mm
Jacket Back Patches (up to 200mm)
Jacket back patches reach the 200mm maximum. A back panel carries a full club crest, motorcycle insignia or brand mark at reading distance. The oversized back patches page explains large-format construction and layout.
Cost factors
How Size and Shape Affect Price
Size and colour count drive the price of a custom PVC patch; shape does not. A larger patch consumes more PVC and raises the unit cost. A custom die-cut outline adds nothing, because the mould is cut to your design either way. There is no minimum order, so single samples and large runs are both available. All prices are quoted in pounds sterling and exclude VAT at 20%. The PVC patch pricing page breaks down every cost factor.
In their words
Stories About Us and Our Customers
PVC patches end up on kit that works for a living. These are the orders behind them, the brief, the mould, and what the patch had to survive.
Tactical · Hook-and-loop
“The patches arrived clean, sharp and ready to go straight onto our kit bags.”
The hook-and-loop backing made it easy for the team to swap patches between packs, jackets and plate carriers without losing the raised detail in the badge.
Sarah Mitchell · Manchester
Workwear · Sew-on
“The PVC badges made our workwear look much more professional than printed logos.”
The sew-on finish gave the uniforms a permanent patch that could handle daily wear, wet weather and repeated cleaning.
James Carter · Birmingham
Streetwear · 3D relief
“The 3D finish gave our caps the premium detail we wanted.”
The raised rubber face helped the logo stand out on the front panel while keeping the colours consistent across the run.
Amelia Thompson · London
Outdoor · Waterproof
“The patches held up well on wet kit and still looked fresh after a muddy weekend.”
Waterproof PVC was chosen for bags and jackets where stitched thread would have absorbed moisture and frayed at the edge.
Oliver Hughes · Bristol
Club · Custom shape
“Our badge shape was unusual, but the final patch followed it neatly.”
The custom die-cut outline kept the club crest recognisable while the moulded edge avoided the bulky border of an embroidered patch.
Priya Shah · Leeds
Security · Velcro
“Being able to remove and replace patches between shifts has been really useful.”
Hook-and-loop backing was selected for staff jackets so roles and identifiers could be changed quickly without replacing garments.
Daniel Evans · Cardiff
Merchandise · Colour match
“The colours matched our brand better than the woven sample we tried before.”
Pantone-matched PVC helped keep the logo consistent for merchandise, reorder stock and event giveaways.
Hannah Wilson · Nottingham
Motorcycle · Jacket patch
“The rubber patch gave the jacket a cleaner, tougher finish.”
The club needed a weather-resistant badge that could handle rain, road grime and regular outdoor use.
Mark Robinson · Newcastle
Sports · Team kit
“The patch worked well on kit bags and training jackets.”
A flexible PVC build kept the team crest visible without adding a heavy stitched border to lightweight gear.
Rebecca Green · Sheffield
Repeat order · Reorder
“Reordering was simple because the mould was already set up.”
The second run kept the same dimensions, relief and colour references as the original patch order.
Thomas Baker · Glasgow
Tactical · Hook-and-loop
“The patches arrived clean, sharp and ready to go straight onto our kit bags.”
The hook-and-loop backing made it easy for the team to swap patches between packs, jackets and plate carriers without losing the raised detail in the badge.
Sarah Mitchell · Manchester
Workwear · Sew-on
“The PVC badges made our workwear look much more professional than printed logos.”
The sew-on finish gave the uniforms a permanent patch that could handle daily wear, wet weather and repeated cleaning.
James Carter · Birmingham
Streetwear · 3D relief
“The 3D finish gave our caps the premium detail we wanted.”
The raised rubber face helped the logo stand out on the front panel while keeping the colours consistent across the run.
Amelia Thompson · London
Outdoor · Waterproof
“The patches held up well on wet kit and still looked fresh after a muddy weekend.”
Waterproof PVC was chosen for bags and jackets where stitched thread would have absorbed moisture and frayed at the edge.
Oliver Hughes · Bristol
Club · Custom shape
“Our badge shape was unusual, but the final patch followed it neatly.”
The custom die-cut outline kept the club crest recognisable while the moulded edge avoided the bulky border of an embroidered patch.
Priya Shah · Leeds
Security · Velcro
“Being able to remove and replace patches between shifts has been really useful.”
Hook-and-loop backing was selected for staff jackets so roles and identifiers could be changed quickly without replacing garments.
Daniel Evans · Cardiff
Merchandise · Colour match
“The colours matched our brand better than the woven sample we tried before.”
Pantone-matched PVC helped keep the logo consistent for merchandise, reorder stock and event giveaways.
Hannah Wilson · Nottingham
Motorcycle · Jacket patch
“The rubber patch gave the jacket a cleaner, tougher finish.”
The club needed a weather-resistant badge that could handle rain, road grime and regular outdoor use.
Mark Robinson · Newcastle
Sports · Team kit
“The patch worked well on kit bags and training jackets.”
A flexible PVC build kept the team crest visible without adding a heavy stitched border to lightweight gear.
Rebecca Green · Sheffield
Repeat order · Reorder
“Reordering was simple because the mould was already set up.”
The second run kept the same dimensions, relief and colour references as the original patch order.
Thomas Baker · Glasgow
Answers
Frequently Asked Questions
Can PVC patches be made in any shape?
YES
Can PVC patches be made in any shape?
YESYes. Custom PVC patches are die-cut to any outline, including irregular silhouettes, internal cut-outs and multi-part profiles, because the mould is engraved to match your artwork.
Do custom die-cut shapes cost extra?
NO
Do custom die-cut shapes cost extra?
NONo. A custom die-cut shape carries no additional tooling cost, since every PVC patch requires a bespoke mould regardless of outline.
Is there a minimum order for a custom size or shape?
NO
Is there a minimum order for a custom size or shape?
NONo. There is no minimum order quantity on custom PVC patches, so any size or shape is available in small or large runs.
What is the size range for custom PVC patches?
25–200MM
What is the size range for custom PVC patches?
25–200MMCustom PVC patches range from 25mm to 200mm, measured as the average of width and height.
Can a small PVC patch hold fine detail?
YES, WITHIN LIMITS
Can a small PVC patch hold fine detail?
YES, WITHIN LIMITSYes, within limits. A 2D patch reproduces text down to 5mm and a 3D patch down to 6mm, so small patches suit bold, simplified artwork rather than dense detail.
Size & shape summary
PVC Patch Sizes and Shapes — Key Points
Custom PVC patches cover every practical size and outline for UK badges and gear. The 25mm-to-200mm range spans cap fronts through to full back panels, quoted by the average of width and height. Standard shapes handle common crests, while die-cut moulding matches any bespoke profile at no extra tooling cost. Smaller patches favour bold, simplified artwork, and larger patches hold fine detail and lettering. Send your artwork with a target size to request a quote, and you receive a digital proof before the mould is engraved.
Return to the PVC patch design guide for artwork requirements, Pantone colour matching and proof approval.
