Introduction: Full Color Flex Patches

There are some logos which can't be stitched. Once a picture is transformed into thread, it will be missing a certain quality, whether it's a sunset gradient, a photo or a character's dozen shades of skin and fur, or a crest with tiny lettering. That's where Full color flex patches come in handy. They create the art in full color on a thin, flexible film, cut the shape into it and allow you to use a heat press to apply it to fabric. The end outcome appears stylish, light and moves with the clothes. https://www.ppai.org/media-hub/when-details-count/ 

This guide will explain you what Full color flex patches are, how they differ from sublimated/embroidered patches, types of full color flex patches, how to create and apply them, cost and where to purchase. 

1. What Are Full Color Flex Patches? 

Full color flex patches are digitally printed patches that we heat apply to a flexible material. One manufacturer says they have "digitally printed" onto a flexible surface, which makes them look like embroidered thread, but maintain a "flat profile”. They will also be available as flexbroidery or printed flex patches. Another maker states that the concept is an embroidered look without embroidery, creating full colour, highly detailed logos, distortion free and no pucker in the fabric.

The characteristics discussed in this section are easy to recall:

• Full color: Gradients, shading and photo-style details reproduce well. RGB and CMYK and Pantone colour codes are generally accepted, but may not be a match.
• Flexible: film will bend and stretch with the fabric and not crack.
• Heat applied: This is done by applying the patch with a heat press (no needle or thread).
• Thin and light: The profile is flat, which means that the patch will not make the cap or jersey look too thick.

2. Full Color Flex Patches vs Sublimated Patch vs Embroidered Patch

Full color flex patches:

• Colour: This should be smooth, flat and slightly shiny or matte with an embroidery look.
• Full colour, including colour gradient, RGB and CMYK and/or Pantone accepted.
• Detail: Fine lines reproduce well, as do small text.
• Durability: Makers claim to be able to last for at least 25 to 50 domestic wash cycles, depending on the product
• Cost at large runs: Low, due to digitizing possibility does not exist
• Fabric: Only heat press, can't be used for any fabric that is sensitive to heat.
• Characteristics: High definition logos, hats and stretchy textiles.Uses: High resolution logos, hats, and stretchy fabrics.

Sublimated patches:

• There is no change in surface, the dye is added to the fabric which remains soft and flat. Embroidered patches look more raised than printed ones and are more difficult to achieve complex designs with.
• Unlimited color range, photo realistic images and accurate Pantone matching available
• Detail: Very high. One embroidery maker specifies a minimum height of the sublimated text as 1.6 mm, while for embroidered text the minimum is 4 mm.
• The durability is good, however printed patches may not be as durable as embroidery when washed heavily. According to one guide, print patches are usually less expensive than embroidered patches, particularly in larger volumes, but have less lifespan.
• Cost at small runs: Usually less expensive than embroidery for multi-color designs
• This product is suitable for application by heat sealing, velcro or sewing.
• For use on: Photographic artwork, complicated brand identities.

Embroidered patches:

• Look and feel: Raised and textured thread in classic and premium look.
• Colours available: Limited, colour of threads. One maker has maximum embroidery colours of 15.
• Detail: Fine detail is difficult and text embroidered is not smaller than about 4 mm tall.
• Durability: The best of the three, particularly if a sew-on backing is used.
• Greater complexity of the design, the higher the cost at small runs, because digitizing is required
• Heat-press (sew-on, iron-on or velcro)
• This fabric is ideal for uniforms, heavy-duty items and classic style clothing.
  https://www.ppai.org/media-hub/when-details-count/ 

3. Types of Full Color Flex Patches . . .  Elaborations

a) By material and construction

• Artwork printed on a flexible film, then cut to shape is Printed flex (flexbroidery-style). This is the WIDELY used 100% color flex patch.
• Molded Flex Patches: Artwork printed as a raised surface which follows the shape of the patch made of thermoplastic material instead of being stitched to a patch of material. More dimension (expensive).
• Print-stitch hybrids: A full colour print on which the embroidery has been added to create texture. These patches are both embroidered and sublimated providing a photograph like image with dimension.
• UV printed hat patches: Full color UV printed patches on leatherette or similar materials, usually available as 2-3" size small patches on hats.

b) By backing

• Low-melt heat seal: This type of heat seal works for thicker materials like jackets and hats, which withstand heat pressing at approximately 320°F.
• Industrial heat seal: stronger seal for uniforms that are washed frequently.
• Pressure sensitive (peel and stick): For surfaces that will not tolerate heat.
• Velcro (hook and loop): Removable and swappable.

c) By finish

• Glossy: Bright colors, as would be the default.
• Matt: A less glossy finish. After removing the carrier one maker says it also gives a more matte finish to the patch if it is covered with a foam pad and re-heated it for 5-10 seconds.

4. Custom Full Color Flex Patches

The format really comes into its own when it comes to custom full colour flex patches as there are no stitch limits. You submit the art, select the size and backing and the patch maker prints, cuts and ships the patch.

There are a few design decisions that determine the outcome of the result:

• Use high-resolution artwork. Sharp printings are made from a clean 300 dpi file or vector file. When images are low resolution, blurs and edges of pixels are visible.
• Select colours, keeping in mind the print. Strong contrast is required for dark background. Color matching is not guaranteed and it's more difficult to match these bright neons and metallics.
• Keep text readable. A small text may not be easy to read in print, so use a minimum of 2 mm tall lettering.
• Choose a shape that will be easily cut. The easiest shapes to cut are circles, rectangles, and simple custom shapes; very thin points break.
• Check the proof. Check for color, spelling and positioning before sending for approval for production.
• Custom orders ensure you a uniform product as well. Patches provide consistency across all garments, whether apparel, team or uniforms, when it comes to colour and detail.

a) Men full color flex patches

Men full color flex patches are typically sports themed, motorcycle style, military, outdoor, gaming artwork and brand logos. Common lengths are 2-4 inches for hats and chest; and 4-6 inches for jackets and back panels. Bright accents on darker backgrounds are excellent for dark hats and jackets, and bold outlines will help to maintain small details from afar.

5. Full Color Flex Patches Review

This review is based on the published specifications and the customers' feedback that are most common, and does not represent one product in particular.

What works well:

• Detail and colour: the most powerful strength. High quality print of photographs, gradients and fine lines.
• Flat and flexible feel: The patch will roll with the fabric and lay flat on caps and jerseys.
• No stitching, no puckering: Avoids a puckered look that embroidery may cause in thin or stretchy fabrics.
• Wash durability: Full color flex patches are rated for 25 or more domestic wash cycles with some even claiming 50 wash cycles or higher.
• Speed and setup: No digitizing required and so small runs are viable.

What to watch for:

• Heat sensitivity: When patches are made from fabrics that are sensitive to heat, they are not recommended for use when heated.
• Color matching: Colours may differ from computer screen to screen.
• Texture: The patch will not be stitched as with embroidery, it will be smooth.
• Laundering limitations: There are laundering restrictions on some patches, such as home laundering only.

Final Recommendation: Full color flex patches are great for patches that need to be colorful and detailed, such as those used on hats, jerseys, and fashion. Embroidered or sew-on patches are a better option for rugged workwear that is laundered in the industrial washing.

6. Uses of Full Color Flex Patches

Full color flex patches are used in a wide variety of products:

• Hats and caps: The most common use, as structured crowns have a flat patch that can be smoothly placed when using a hat or cap.
• Patches for jackets and hoodies: Patches for chest, sleeve and back for streetwear and outerwear.
• Team gear / uniforms: crest, sponsor logos, numbers using exact brand colours.
• Canvas and nylon bags and backpacks: Colorful branding.
• Gift items: giveaway items, event equipment, and employee shirts and pants.
• Add a detailed logo without having to setup for embroidery with a low minimum size or price.
• Retail ready products: Hat bars, print shops use to make custom products on demand.
  https://graphics-pro.com/education/heat-applied-graphics-trends/ 

7. Why One Should Use Full Color Flex Patches

There are a number of valid reasons why it is better to select full colour flex patches in preference to other patch designs:

1. Unlimited color. The thread colors are applied to embroidered patches and flex patches can be printed any color and/or gradient.
2. Fine detail. The stitched patches do not reproduce as well as small text and delicate lines.
3. No digitizing. The digitizing process is not required, thus reducing set-up time and cost for small runs.
4. Flexibility. Patch can be moved along with the fabric - usable on stretchy garments.
5. Consistency. To maintain uniform brand colors, each patch corresponds to the previous patch.
6. In-house application. Using a heat press allows you to attach patches yourself, and avoid the shipping delay.
7. Low profile. The patch is light and thin, and will not bulk up a cap or jersey.
   https://members.asicentral.com/news/how-to/july-2022/elevate-your-apparel-with-these-4-heat-transfer-trends/ 

8. How to Make Full Color Flex Patches

a) The professional process

Prepare the artwork. Yes, they accept RGB, CMYK and Pantone colour codes and clean files are best.

1. Cut the design to shape with scissors and stick to the paper.
2. Add the finish. The surface layer is either glossy or matte and serves to protect the print.
3. Using laser cutting or cutting plotter, cut the shape.
4. Cut away the excess film.
5. Add the backing. Low melt heat seal, industrial heat seal, pressure sensitive adhesive or velcro.
6. Examine the color, edge and stickiness.

b) DIY approach

In an easy version, it can be used at home, on a printable heat transfer sheet.

You will need:

• Printable heat transfer film and an inkjet printer capable of printing the film.
• Registration capabilities of a cutting machine that can be used for print and cut.
• Tools
• A heat press that attaches to a cap, or a household heat iron.
• A protective sheet

Steps:

1. Plan your artwork in the final size without having to do it in miniature.
2. Follow the transfer film's directions to print it on the transfer film.
3. Cut around design using print and cut setting.
4. Trim off the extra film.
5. Try it out on a piece of spare fabric before using it on the actual object.

DIY patches are fine for small personal or projects. They will not be as thick, edge, and washable as professionally made flex patches, please order custom for gifts, sales and brand work.

9. How to Apply Full Color Flex Patches

The common and standard technique is the heat pressing. Each setting patch and press will be different, so always try a patch and press with a spare item before using it on your setting or press. Common advise is to use this:

When printing on hats (hat heat press):

• First use, heat lower platen for 60 seconds, load cap, and heat cap for 20 seconds, then place a flex pad on top of the patch, and press.
• The one with a low-melt backing has about 275 to 285°F at the top platen and 315 to 320°F at the bottom platen with 60 to 80 psi pressure applied for 15 to 18 seconds. Do not put the inner layer of the cap in the press zone.

For clothing (on top heat crib):

• Around 355 to 365°F at 40 to 50 psi.
• Heat the garment first for about 15-20 seconds and then press the patch on it for 15-20 seconds.
• If it is specified in instructions, press the garments outwards the second time.

After pressing:

• Allow the patch to dry and then peel off the clear carrier.
• To achieve a more matte finish, cover and re-heat for 5-10 seconds using a foam pad.
• Do not wash before, and wash outwards in cold water.

Fabric tips: Heat applied patches are best applied to thicker fabrics such as jackets and caps that can withstand approximately 320°F. Be sure to test the patch for lifting at edges after first wash; avoid heat-sensitive fabrics.

10. Full Color Flex Patches Pricing

Full color flex patches pricing is based on size, quantity, backing and finish. The following are typical ranges for a 3” patch;

Single piece or sample: $5-$9 per piece or sample based on the quantity and quality of the items.

• 25 pieces: About $3.50 to $5.50 each
• 50 pieces: About $2.90 to $4.50 each
• 100 pieces: About $2.40 to $3.90 each
• 250 pieces: About $1.90 to $3 each
• 500 pieces: About $1.60 to $2.70 each
• 1,000 pieces: About $1.30 to $2.20 each

What the market is in examples published. About $3.20 each for a full colour print patch (no minimums) and about $3.50 each for a UV print patch (no minimums) from 2 different makers. Wholesale UV-printed leatherette hat patches start as low as $2.25 each. The molded flex patch is a raised surface and is more expensive, about $5-$23 per patch, depending on the patch size and quantity.

A change in the price is caused by:

• Size: The larger the patches, the more amount of film is used.
• Quantity: If you place a bulk order, the price of each patch goes down significantly.
• Backing: Standard heat seal, velcro and industrial heat seal may incur an extra charge.
• Finish &a shape: Custom die-cuts special finishes are more expensive.
• Rush production is more expensive due to the quicker turn-around.
• To save money, consider sizes of less than 3” or standard shapes, and order in larger quantities.

11. Sourcing/Buying Guide: Where to Buy

a) Full color flex patches Rush Patch

Rush Patch has flex patches as well as full colour printed patches, so they might be able to create a full colour flex patch for your artwork. All orders come with a complimentary AI proofing prior to manufacturing, and a complimentary roll of thermal tape for self-pressing. Standard production ships in 9-13 business days after proof approval, patch types can ship in 5 business days with rush production and shipping is free for orders over $200.

For a patch type check the cost, use the pricing calculator on the patch page for each patch type: https://rushpatch.com/ . Wholesale rates are offered to schools, businesses, military units and brands and the team can assist with artwork.

b) Full color flex patches amazon eBay

People typically compare Amazon and eBay, and they're both for a different purpose.

Amazon: Amazon offers patches made ready to print and affix, blank patch material and supplies for the heat transfer process for do-it-yourself projects. It's quick and easy to ship and easy to see the quality against other reviews. Read listing to ensure it is a full color printed patch (not an iron-on patch) and size, backing and customer photos. Amazon is the best for stock patches and supplies, as there are few custom orders. Search here: https://www.amazon.com/s?k=full+color+flex+patches 

eBay: eBay is great when selling the patches in small quantities that have been applied to items with heat; and for rare designs. Send e-mail to the seller to discuss size, backing and compatibility with fabric, and request a picture of the patch. Read feedback and return policy and ensure deliveries are in time as can take weeks for overseas shipping. Search here: https://www.ebay.com/sch/i.html?_nkw=full+color+flex+patches 

Conclusion 

Full color flex patches offer the best of both worlds, print detail and flex applied patch. They transfer well using a heat press, embroidery cannot do that with gradients, small text or bright colors. They have the look of an embroidery on a flat surface, and when compared to embroidered patches, have a reduced price for more intricate art, but don't have the raised texture. Custom patches will cost around $5 to $9 per patch and drop to around $1.30 to $2.20 per patch when ordering 1,000 or more. Test one patch on real fabric and follow press settings and you'll come up with a sharp looking patch with wearability.

Looking to create your own? Create and see a proof of your custom patch before ordering.