I’m going to address some common questions about how personalised patches are made.

So here’s the process

1 – We need a design. More importantly, we need a Vector design (i’ll explain more on this)

2 – We need to 3D render the design

3 – We need to “cut” the design from metal plates

4 – We produce a test patch

5 – We make the required custom pvc patches and get the velcro added to them

6 – We send them out to you awesome people

Design stage

I said I’d explain this as this is really important.

“I have a low resolution png/jpeg design – can you make my custom patches from this?”

Well, sometimes yes and sometimes no. I mentioned “Vector” design before. The main difference between vector and raster graphics is that raster graphics are composed of pixels, while vector graphics are composed of paths. A raster graphic, such as a gif or jpeg, is an array of pixels of various colours, which together form an image. Raster images are usually OK for embroidery, but for Custom PVC patches we always need a vector design.

Raster vs vector image for pvc patches

Think of it like a digital outline, that the CNC machine can follow.

If you send over a raster image (jpg or png) then we still have to re-design it in a vector format. Some take a few minutes (nice and simple ones) and some can take hours and hours. We don’t want to charge extra but time is money! Sometimes we have to charge. If you have a raster image and you want it as a vector file quite cheaply – head over to https://www.fiverr.com/ and search for “vector tracing”.

Then send us your vector file (SVG, AI or EPS files) and we can crack on with 3D rendering the image.

3D rendering of the patch design

Once we have the 2D vector design, we need to 3D render it, so that the CNC machine knows where to cut. Here’s a couple of example of the 3D rendering for Airsoftparts Online and Team Kamikaze.

CNC Machining of the design

Once we’ve done all the above, the design heads to the CNC machine. This cuts out the “negative” of your custom design.

Custom PVC patches – CNC machining

Once the design has been cut, liquid PVC is poured into the mould, then set. We’re then left with a test patch.

You’ll see from the picture that there is a “gully” towards the outer edge. This is where the stitching will eventually go, to attach the velcro.

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