Find Type & Size
Best if you're starting from scratch. We'll recommend both the patch type and a proportional starting size.
Need General Size Charts?
Looking for Standard Sizes by Placement?
Use the Patch Size & Placement Guide to compare common sizes for hats, chests, sleeves, jackets, bags, uniforms and more.
Open the Size GuideWhat Is the Patch Advisor?
The Patch Advisor is a free tool that recommends a patch type and a starting size based on your actual artwork, where the patch will go, and how it will be used.
Most patch orders start with a guess. You pick a type from a list, choose a size that sounds about right, and find out whether it worked when the sample arrives. That guess is where most reorders come from.
We have been making patches since 2015, so the advisor is built on what we see in production every day. Which designs hold their detail in thread. Which ones lose it. What actually fits a cap front compared to a jacket back. Upload your design, answer a few short questions, and take the recommendation straight into a mockup.
- Personalized to your design
- Original proportions preserved
- Reviewed before production
How We Find Your Best Match
Your recommendation is based on the details that matter most in production and everyday use.
Artwork Detail
Fine lines, small lettering, gradients, bold shapes and overall complexity.
Use & Environment
Everyday apparel, workwear, outdoor gear, uniforms, hats, bags and more.
Look & Feel
Classic thread, smooth PVC, fine woven detail, plush chenille, leather texture or full-color print.
Size & Placement
The available space, your artwork's proportions and where the finished patch will be worn.
Attachment
Sew-on, iron-on and hook-and-loop options based on the patch type and intended use.
Why Use a Patch Advisor Instead of a Size Chart?
A size chart tells you what other people usually order. The advisor tells you what fits your design.
How the size is decided
On your own
A generic chart that never saw your artwork
With the Advisor
A size built from your design's real proportions
How the type is chosen
On your own
Pick a patch type from a list and hope it suits the design
With the Advisor
A type matched to your detail level, placement, and how it will be worn
When you find out
On your own
Find out it was wrong when the sample arrives
With the Advisor
See the size on the item before you order anything
How long it takes
On your own
Back and forth emails to get an answer
With the Advisor
An answer in about a minute, with no account needed
What comes first
On your own
A quote first, advice later
With the Advisor
Advice first, and nothing charged until you approve your mockup
None of this locks you in. The recommendation is a starting point, and our team confirms every detail with you on the mockup before production.
Compare Custom Patch Types
Here's a quick look at what each patch style does best.
Embroidered Patches
Classic stitched texture for bold logos, clean shapes and an authentic patch look.
Woven Patches
A smooth thread finish for fine lines, small lettering and detailed logos.
Glow-in-the-Dark PVC Patches
Weather-ready PVC with glow details that stay visible in low light after light exposure.
PVC Patches
Flexible, weather-resistant patches built for outdoor gear, uniforms and demanding use.
Chenille Patches
Soft, raised varsity texture for large lettering and bold statement designs.
Leather Patches
A clean, premium look for hats, apparel, bags and branded accessories.
Printed Patches
The best fit for gradients, photos and highly detailed full-color artwork.
Which Patch Type Fits Your Design?
The embroidered vs. woven patches question usually comes down to detail, while PVC vs. embroidered patches comes down to where the patch will live. Here's a quick comparison.
| Patch type | Best for |
|---|---|
| Embroidered Patches | Classic stitched texture and versatile everyday branding |
| Woven Patches | Fine lines, smaller lettering, and detailed logos |
| PVC Patches | Outdoor, tactical, weather-resistant, and high-use applications |
| Glow-in-the-Dark PVC Patches | Bold designs that need glow details in low light |
| Chenille Patches | Large letters, mascots, varsity jackets, and team apparel |
| Leather Patches | Minimal, premium, rustic, or heritage branding |
| Printed / Sublimated Patches | Photographs, gradients, illustrations, and complex colors |
Patch Size Recommendations Based on Placement
There is no single correct patch size. The right dimensions come from five things working together: your artwork proportions, the garment or item itself, the placement you choose, how complex the design is, and how much visual impact you want. A tall crest on a cap front behaves very differently from the same crest on a jacket back.
Patch size for hats is limited by the crown panel, so wide, short layouts read best. Cap fronts stay modest; cap sides and backs are smaller still.
Patch size for jackets scales up quickly. Back panels carry large statement patches, while chest and sleeve placements stay in the same range as shirts.
Patch size for uniforms usually follows an existing standard for name tapes, rank, and unit or company marks, so consistency matters more than maximum size.
Detailed designs need a little extra room. If your logo carries small text, the advisor will lean toward a size and construction that keep it legible.
Want visual references? See the custom patch size chart, check the recommended cap patch sizes if you're sizing a hat, browse custom patches, or take your numbers straight into a .
Patch Advisor FAQ
What is the Patch Advisor?
The Patch Advisor is a free tool from 6Six Needles that recommends a patch type and a proportional starting size based on your artwork, placement, and intended use. No account is required, and you only pay after you approve your mockup.
Is the Patch Advisor free to use?
Yes. The Patch Advisor is completely free, no account is required, and you only pay after you approve your mockup.
What does the Patch Advisor recommend?
It recommends a patch type and a proportional starting size based on your artwork, placement, intended use and preferred finish.
Do I need finished artwork?
No. You can upload finished artwork, a sketch or a reference image, or simply describe your idea if you do not have a file yet.
How is the recommended size calculated?
The advisor considers the available placement area and your artwork's original proportions. It recommends Width × Height without stretching or cropping the design.
Can I change the recommendation?
Yes. The recommendation is a strong starting point that you can adjust at any time, and our team confirms the final patch type, size, backing and production details during your mockup review.
What is the minimum order?
Embroidered, Woven, PVC, Glow-in-the-Dark PVC, Chenille, Leather, and Printed / Sublimated patches start at 5 pieces. Your recommended patch type will show its correct minimum.
Ready to See Your Patch?
Use your recommendation to request a digital mockup and review your design before moving forward.
Get My MockupFree to use. No account required. No payment until you approve the mockup.
Need embroidery instead of a patch? Try the Embroidery Digitizing Advisor.