Introduction: Metallic Flex Patches

Some of the patches are stitched, some are woven and some appear to be cut in liquid metal. Metallic flex patches are part of the latter category. They are shiny, dimensional, won't crack when bent over the cap or jacket, and won't require a needle and thread to operate. This combination of style and functionality is leading to their presence on the streets, in team uniforms, and on brand products.

In this guide, you'll learn what metallic flex patches are, the main types of flex patches, how they're made and applied, cost, and how to buy flex patches. 

1. What Are Metallic Flex Patches?

Metallic flex patches are patches cut from a flexible and metallic finish surface material that are heat applied. They are created from a versatile, sturdy fabric that will stretch and mould with your clothes and provide a contemporary, stunning look for hats, garments, uniforms and custom branding. The finish creates a metal-like 3D effect and sharp edges and custom shapes. 

The same product can be referred to by several different names:

• Metflex patches: Metflex patches are a popular term for metallic flex patches.
• Metallic Patch: A more general term that may refer to patch stitched with metallic thread or woven with metallic yarn.
• Flex patches: Metallic, chrome, matt and full colour patches of flexible film that can be heat applied.

A flex patch is similar to a patch but differs in that it has no stitching and no thread border. The design is cut in one piece, edges are sharp and fine details are preserved.

a) Flex embroidery Patches

Flex embroidery Patches (also known as flexbroidery) is related style. They are sewn on and have the flexibility of a flex patch but look like embroidery. Some manufacturers say they come in vibrant, unlimited colours and are ideal for apparel, accessories and uniforms, and they are heat-press patches. The design also has no restrictions on colors of the threads, so it's suitable for detailed stitched logos and gradients that would be very costly.

• They are easily distinguishable just by looking at them:
• Embroidered patches: Made from thread and raised and textured.
• Metallic flex patches: Made out of film, and have a smooth, shiny appearance.
• Flex embroidery patches: These patches are made from film, but have been designed to appear as embroidery.

2. Types of Metallic Flex Patches

a) By finish

The first thing to select is the finish. These are typical flex styles: metallic flex, full colour printing flex, matt black flex, matt white flex and chrome flex. Here are some of the differences:

• Metallic flex: Shiny, high-quality metal in different colours, including silver, gold and rose gold.
• Chrome flex: provides most reflective and high gloss, mirror glass 3D shine. This is the most daring alternative.
• Matte flex (black or white): Black or white and has no metallic sheen, suitable for simple branding.
• Full-color printed flex: Printed design on flex film, for logos that have a large number of colors.

b) By profile

Some manufacturers use the same metal in various shapes, including flat, domed, beveled, and textured. There is a flat patch, a domed patch with a smooth bubble effect and a bevelled or textured patch which adds detail to the edge. Domed hats and hard goods are suited to domed shapes, and flat hats and jerseys/uniforms are suited to flat shapes.

c) By backing

The backing determines the type of attachment for a patch:

• Heat-seal backing: The conventional option, which is pressed onto the heat-seal.
• This is for use with thicker items like jackets and hats that can be heat pressed at approximately 320°F.
• Velcro (hook and loop): Only with metallic and non-metallic flex and not for all finishes. Swap patches good for.
• Peel and stick: For surfaces which cannot withstand heat.

d) Metal hat patch blanks

Metal hat patch blanks are another product designed for the do-it-yourself crowd using a laser engraver to create the patch. They come as simple patches that need to be engraved and an adhesive is already applied to the back. A good example is a round blank that is double-sided and will show the metallic silver layer underneath the matte black top coat when engraved. This is a high contrast metallic reveal effect that appears to be a high quality debossed finish.

Other blanks available have metallic and leatherette finishes, acrylics, and layered engraving sheets, and engravable laser foil is a thin mylar tape with a permanent adhesive that gives small text a “pop” effect and adds metallic finishes. A pack of ten laser blanks is approximately $20 in one listing so an approximate $2 per blank making it a low-cost testing of a design.

3. Metallic Flex Patches vs Custom Metallic Flex Patches

Metallic flex patches:

• Design: Seller selected shapes and logos that are pre-made
• Ease to use: Easier to use, usually $2-$5 per patch.
• Utility: Low, but these are useful items for the home that can be reproduced with a great deal of ease.
• Originality: Low, many people buy the same designs.
• Minimum order: No minimum order, or only a few pieces are allowed.
• Turnaround: 'Is ready for delivery'
• Pros: Easy to install, low cost, small scale testing, and quick upgrades.
• Cons: Limited size, application, and warranty.

Metallic Flex patches:

• Design: Your own artwork, shape, colours and finish
• Cost: The more expensive the smaller orders, the less expensive the larger orders.
• Uniqueness: High
• Minimum order: a low minimum order, typically 10-50 pieces.
• Turnaround: 1-3 weeks (some patch makers can provide 24 hours turnaround on certain patch types)
• Ideal for branding, teams, uniforms and merchandise.

Purchase stock patches when they are on sale and at a reasonable price. Order custom in design when it is appropriate to use your name.

4. Custom Metallic Flex Patches

a) Custom metallic flex patches: designing and ordering

Custom metallic flex patches begin with your art work and there are some design factors which can make the difference between a crisp patch and a chaotic patch.

1. Prepare the artwork. Use a vector file (Illustrator, SVG etc) that has clean outlines. All of the shapes must have a distinct border, as the patch is made from a single piece of film. Minimize any gradients that are not required.
2. Be careful of the cuts. Space is required for lettering. Another maker says that the only spacing that gives a good cut is a 1 mm or greater separation between letters; compact letter spacing may lead to the letter being cut together or to very small and fragile letters. Try not to use very thin lines or very small islands as in the inner of an "A" or "O" at the smaller sizes.
3. Select finish & color. The classics are metallic silver and gold. Chrome is bolder; matte black or white are suitable for minimalist logos. If your logo is heavily coloured, you may want to use a full colour flex instead of a metallic colour.
4. Pick the size. The width of hat patches typically is 2-3.5 inches, jackets and bags 3-6 inches and larger back patches larger. Look at the prices, as it is size that can be a significant driver of cost.
5. Select the backing. Use heat-seal, velcro, and pressure-sensitive for different bonding applications when heat is not an option.
6. Approve a proof. Spell, space, and color and then order. Most of the makers will provide a digital proof prior to cutting, and some will even provide sample packs so that you can sample the material before a large order.

b) Custom metallic flex patches: for brands, teams, and small runs

For businesses and groups, custom metallic flex patches are a great option as they are quick to manufacture and have low minimums. Essentially, the following are the various ways buyer uses them:

• Logos on caps, jackets or hoodies that are metallic will add a premium touch to any look; it will be noticeable in photos. Flex patches are favorites due to their flexibility that works well with flexible fabric.
• Sports teams or clubs: colors, chrome or metallic numbers, crests and logos from sponsors on jersey and warm-ups with the same color as the team.
• For corporate or promotional applications: Caps and jackets that are branded to employees, events and souvenirs, where the shine can be seen from far away.
• Small runs and tests: A short run of 10-50 patches allows you to test out a design before ordering hundreds, good for when you're unsure of your design.

The clever purchasing method is the following:

1. Order a sample first! Place one patch on a real hat or coat, and clean it.
2. Select your size and completion. Select appropriate size, finish and backing from the sample.
3. Run a medium sized one. Check the sales results or reaction of the patches with 50-100 of them.
4. Scale up. If the design is successful, purchase 250 to 500 additional pieces for a reduced per patch cost.
5. Reordering also is easy. Be sure to keep your vector file for the next time you create a batch, and it will be exactly like the first one! If you're in the hat or clothing business, press them in-house to avoid shipping and to have control when they're ready 

5. Uses of Metallic Flex Patches

Metallic Flex Patches are more than just for hats. They are light, flexible and heat applied and can be used on a variety of items:

• The most popular usage is for hats and caps. Any patch made of metal or chrome on the front panel or side will elevate the appearance of a cap, making it look high quality.
• Jackets and hoodies: Patches for the chest, sleeves and back of jackets and hoodies.
• Uniforms and workwear: Name, rank and logo patches which remain shiny and legible.
• Sports jerseys and team equipment: Crests, numbers and sponsor logos that move with the fabric.
• Bags and backpacks: Patches of the brand on canvas and nylon.
• Items for sale: T-shirts, caps, bags, backpacks, and other items used during events and offered for sale.
• Flexible emblems: These are some of the emblems that can be attached to various surfaces such as fabric, plastic, glass, and are meant for dishwasher and home washing machine use and are flexible. They're well suited for drinkware and equipment.
• Fashion & DIY: Creating a metallic accent for denim, tote bags and accessories.

6. How to Make Metallic Flex Patches

a) The professional process

The sequence of the professional production is:

1. Make artwork using vector file with clean shapes.
2. Select metallic, chrome, matte or full color flex film.
3. Cut the shapes. The design is cut out of the film using a cutting machine or laser, along the outline of the artwork.
4. Weed the excess. The unwanted film off the design is taken off.
5. Add the backing. There is a heat-seal adhesive (or velcro or pressure sensitive layer) on the back.
6. Layer or finish. Multi-layer designs are stacked and surface finishes are added, if necessary.
7. Inspect. Before packing, the following is checked: edges, adhesion and color.

Makers can also create the patch using a mold. With domed shapes, a digital sample is approved and then the mold can be created in one day and setup is faster. Another method to creating metallic effects within a patch is to use metallic thread to embroider into the patch, which is typically more expensive. One maker charges 25% over the price of the basic cloth for using metallic thread.

b) How to make Metallic Flex Patch - DIY approach

It is possible to design your own metallic patch using a craft cutting machine and metallic heat transfer vinyl, a relative of true flex film.

You will need:

• A cutting machine and cutting mat.
• Metallic/Chrome Heat Transfer Vinyl (and Adhesive Sheet for patch backing)
• Tools
• An iron for heat-pressing or an iron with a hat attachment
• A protective sheet

Steps:

1. Create a design that includes a basic shape with strong lines.
2. Cut out the design from the metallic vinyl.
3. Trim away any overgrowth.
4. Back the piece to ensure that it can be pressed to form a patch.
5. Take a sample of material and try out the patch.

While it better suits to single use, the cost of DIY flex patches is much costlier than the professionally manufactured flex patches with the same thickness, edge finish and durability. If you are in need of a lot of logos, art or anything you want to sell, then it is better to order custom patches.

If you want to use the laser, purchase hat patch blanks that are adhesive backed, engrave your design and then peel and press.

7. How to Apply Metallic Flex Patches

To apply metallic flex patches, a heat press is the ideal option as it is a heat applied process. The patches are heat-applied and you use a heat press and follow the instructions to press the patch given with your patch style. .Always check your maker's instructions as settings will differ from patch to backing and backing to backing. It is typical guidance that looks like this:

For hats (using a hat heat press):

• Put the hat on press with the inner layer of the cap not in the press area.
• Set the top heat to about 275 to 285°F and the bottom heat to about 315 to 320°F, with 60 to 80 psi of pressure.
• Press for 15 to 18 seconds.
• Allow the patch to cool, and then peel off the clear top carrier.

When pressing garments (from a top heat press):

• Set the press to about 355 to 365°F at 40 to 50 psi.
• Put the garment into a heat pad (silicone pad) and preheat for 15-20 seconds.
• Press the patch for 15-20 seconds.
• Allow to cool before peeling off the carrier.
• For velcro backing: Sew or fuse velcro loop onto your item and then fuse velcro patch. This will make it removable.
• If using a pressure sensitive backing: Remove paper, press it down hard and hold.

To get a clean result add the following tips:

• Test first. Test on a spare piece of fabric as heat and pressure can scorch another fabric if they are used on the same. Makers suggest checking your particular material prior to production.
• Select the appropriate fabrics. Low melt patches work well with thicker fabrics such as jackets and caps that can withstand up to 320°F. Do not use heat-sensitive or waterproof fabrics.
• Protect the surface. Silicone Pad or Protective Sheet will prevent scuffing of chrome and metallic films.
• Do not move the item until it is completely cool.
• Wait before washing. Allow adhesive to dry, then wash inside out with cold water.

8. Metallic Flex Patches Pricing

The price of metallic flex patches can vary based on size, finish, backing and quantity. A general guideline to consider: A 3" custom metallic flex patch is approximately:

• 100-piece bulk: 10 per cent discount on the above price.
• 25 pieces: About $3 to $5 each
• 50 pieces: About $2.60 to $4.20 each
• 100 pieces: About $2.20 to $3.60 each
• 250 pieces: About $1.80 to $2.90 each
• 500 pieces: About $1.50 to $2.50 each
• 1,000 pieces: About $1.20 to $2 each

Laser blanks can be found for $2 each. Metallic thread embroidered patches are a little more expensive due to the additional cost of the thread, which is approximately 25 percent.

The following factors affect the price:

• Size: The larger the patch, the more material is needed.
• Specialty films and chrome are more expensive than matte.
• Detail: Complicated cuts require more time.
• Backing: Most often heat-seal is included, velcro is an extra cost.
• Setup: Some manufacturers offer a setup fee or built into the estimate.
• Bulk orders substantially reduce the patch price.
• Save money by ordering in larger quantities, a regular shape and under 3 inches.

9. Buying Guide: Where to Buy

a) Metallic Flex Patches, ebay

Stock metallic flex patches, blank hat patches and those who sell custom patches in small quantities are available at eBay. You can view by finish, size and backing, and you can message sellers about custom orders. Check for "heat applied" or "heat seal" on listings, and verify the patch with a photo of the actual patch.

Look at the seller's feedback and return policy, and shipping times, if the seller is from overseas, they may take a few weeks. Inquire about a sample image prior to custom order. Search here: 

b) Metallic Flex Patches, Walmart

Iron-on patches or heat applied, blank hat patches, craft supplies from brands or marketplace sellers are available at Walmart. A nice spot to purchase small amounts of stock patches or blank patches used for do-it-yourself projects at a low price.

When choosing a patch, read the product description to be sure it is heat applied and the material it is made from; heat applied metallic may refer to a foil finish or a metallic thread or a flex film. Look at the seller's information, delivery time and return policy. Browse here: 

Conclusion 

You can get a bold, reflective look without the needle in metallic flex patches and the finishes are quite varied, including metallic, chrome, matte and full color. Flexible, heat applied and ideal for hats, jackets, uniforms and merchandise. If you are doing something custom, ensure you provide clean vector artwork, leave space between the letters and make sure you get a sample before you scale up. 

Expect to pay anywhere from $4 to $8 per custom patch, dropping to about $1.20 to $2 per patch at 1,000 pieces, then pressed with a protective sheet at the proper heat, pressure and time. If purchasing stock patches on Walmart or eBay or ordering custom, do test on a real item in order to make sure that it looks the way you want.

Looking to create your own? Create customized patches now and see a proof before you place your order.