I run an embroidery factory in Pakistan and get this question constantly from brands sourcing patches for the first time, so figured I'd break it down here instead of in another DM.

Three things drive cost and quality on a custom patch:

1. Stitch density. Cheap patches skip fill stitches on large areas — looks fine in photos, falls apart after a few washes. Ask your supplier for density specs, not just a mockup.

1. Thread type. Rayon thread has a nice sheen but frays faster. Polyester holds up way better for workwear/uniforms that get washed a lot. If your supplier doesn't ask which one you want, that's a red flag.

1. Backing. Iron-on is fine for low-contact apparel. Velcro is worth the extra $0.20-0.30/unit if the patch is going on gear that gets swapped often (jackets, bags, uniforms with interchangeable branding).

Biggest mistake I see: brands ordering 500+ units before ever seeing a physical sample. Always get a stitched proof, not just a digital mockup — digitizing can shift small text and fine details in ways a flat image won't show you.

Happy to answer questions if anyone's sourcing patches for the first time.