Introduction:

Today PVC Patch Maker Machines have become common because they are used on caps, tactical bags, jackets, uniforms and brand products. It shouldn't come as any wonder that many small enterprises are desiring to produce them in-house. PVC Patch Maker Machine is a piece of machinery that mould, fill and cure the PVC material into the durable three-dimensional patches.

In reality, however, a complete configuration is generally not one piece of equipment. A small series of machines and tools which work together from mould to curing to finishing.

In this guide you'll learn:

• The concept of PVC patches and how to create them.
• Materials and methods required to make PVC patches; how Liquid PVC for patch making works.
• What kind of machines you may require, and the cost of a patch making machine.
• Selection of the appropriate set-up, and when it is better to outsource

1. What Are PVC Patches and How Are They Made?

a) What PVC patches are?

PVC patches are patches that are created by molding https://formlabs.com/blog/how-to-make-a-mold/  and forming colored PVC to create a soft and flexible rubber-like patch. They are constructed from multiple layers of liquid material that harden into a solid surface that will not pucker, wrinkle or be ruckled like an embroidered or woven patch. The outcome is a colorful, 3D textured, modern and clean design. https://en.wikipedia.org/wiki/Polyvinyl_chloride 

They are popular because they will keep up well in the outdoors. They are waterproof, dirt-proof, and fade resistant and they can be created in virtually any form. Embroidered patches look like they have threads and are made in a textile fashion, woven patches look flat and fine, PVC patches give a sculpted and rubbery finish, which is perfect for tactical gear, sportswear and streetwear.

b) The PVC patch making process at a glance

Each PVC patch contains the same series of steps:

1. Artwork: clear separation of colours and shapes.
2. Mold making: A mold is formed which is a cast of the shape and any raised detail.
3. Color filling: Liquid PVC is poured into the mold, sometimes in layers, in various colors.
4. Curing: Heating the filled mould to make the PVC solid.
5. Trimming: any material that is surplus removed and edges cleaned up.
6. A backing of an appropriate material, e.g. hook and loop, glue, sew-on or iron-on is used.

Specific equipment is required for each stage of the process and that is why the rest of this article is devoted to the materials, machines and costs.

c) Why businesses make PVC patches in-house

Creating patches in-house will allow you to control the quality, order them more quickly for urgent requests and to order small, custom batches without waiting for a supplier. It can also help to boost margins for a growing brand when sales levels are stable.

But there is a cost to this. It takes time to get the hang of it, equipment is a big investment, and there are some regular expenses such as materials, molds and maintenance. Many businesses begin by outsourcing "just enough" to meet demand and eventually move production into the company when the need for the products becomes great enough.

2. What Is Needed to Make PVC Patches?

a) What is needed to make PVC patches?

The materials needed to make PVC patches are PVC material, molds, PVC dispensing and coloring devices, a curing oven and backing materials. The rest of the equipment includes trimming tools, a well-ventililated work area and simple safety tools. They all serve different purposes and omitting any usually reduces the quality and production speed.

Here are some actionable steps to take:

• Liquid PVC compound: main material, which becomes the patch once cured.
• Color pigments: Used to mix brand artwork colours.
• Molds: These are metal, silicone or 3D printed molds that determine the shape of the patch and its detail.
• Dispensing or filling tool: Use of a manual syringe or automatic dispensing machine to place the PVC into the mold. Automatic machines come from specialist makers such as Dongguan Jinyu Automation Equipment, which offers dispensers from 8 to 24 colors. Another example is the LIXIN LX-P800 from Guang Dong Li Xin Intelligent Technology, a 12-color unit with ±0.01 mm positioning and a 12-month warranty. https://www.jinyumachinery.com/dispensing-machine/ https://www.alibaba.com/product-introduction/Soft-Rubber-Pvc-Logo-label-Automatic_60586543106.html
• Curing oven or heating plate: Hardens PVC by careful application of heat. Dedicated intelligent PVC ovens are sold by the same suppliers that make the dispensers, so buying both together makes setup easier. https://www.jinyumachinery.com/intelligent-pvc-oven/
• Trimming tools: Scissors, cutters or dies that are used to clean the edges.
• Backing material includes: Hook and loop, adhesive, sew-on fabric or iron-on film.
• Safety Equipment: Gloves, eye protection, ventilation.
  https://www.nist.gov/mep/additive-manufacturing3d-printing 

b) Materials and consumables

In addition to the PVC itself, you will be regularly applying pigments, backing materials, cleaning solvents and mold-release products. Consider consumables when planning, calculate the amount of material required for each patch and multiply by the usual batch size of material. Always leave a little headroom, because there will always be more mixing and testing of colors needed than you think.

Storage matters too. Store PVC and pigments in sealed containers, out of direct sunlight and heat and ensure the shelf life is not exceeded before ordering large quantities. Be sure to name each colour distinctly to ensure that you are able to reproduce the colour in subsequent orders.

c) Tools, workspace, and safety

It is very important to have a clean and well-ventilled work area. Always read the material safety data sheet provided by the supplier and good ventilation or an extraction system is advised for PVC fumes to be released during heating. Refer to provincial/territorial workplace safety and handling standards these vary by province/territory.

A starter workspace checklist (checklist for a workspace to get started):

• Strong Heat Resistant Work Table (16" x 16" x 8")
• Problem: Insufficient ventilation or fume extraction. Solution: Good ventilation or fume extraction.
• eye protection.
• First aid kit and Fire Extinguisher in immediate vicinity
• Temperature control and Timer for curing
• Mold, material and finished patch storage shelves

3. Liquid PVC for Patch Making

a) What liquid PVC is and how it works

Liquid PVC for patch Making is used to make patches, it is a fluid compound known as plastisol which is poured into a mold and heated until it firms up and becomes flexible. When heated, it liquefies and flows easily, and can be layered and colored at the same time. It is cured into a long-lasting, rubber-like adhesive. https://en.wikipedia.org/wiki/Polyvinyl_chloride 

It's a good choice for patch making for a couple reasons. It is able to replicate intricate details and sharp lines, retains vibrant color and does not crack or become brittle. It also fuses the layers together which is how multi-colour and raised designs are created.

b) Choosing and handling liquid PVC

This will depend upon the appearance and feel you desire. Consider these options:

• Hardness (softness): Softer compounds are rubbery and flexible, harder compounds have sharper shapes.
• There are two examples of translucent versus opaque PVC: Translucent PVC can create layered, glass-like effects, while opaque PVC provides bold colors.
• Variety can be achieved through the addition of special effects such as glow in the dark, metallic or reflective.
• Precise pigment ratios ensure consistent colours between batches:
• Handling is crucial to quality. Precisely measure pigments, mix slowly to avoid air pockets and allow material to rest in case of air pockets. 

Buying tips:

• Select the supplier that has demonstrated a good reputation and has product information. Ready-made dripping-grade plastisol exists, for example PECOAT 2564 PVC plastisol paste, which is formulated for the dispensing (micro-injection) process. https://www.thermoplasticcoating.com/product/pvc-plastisol-paste-for-patch-badge-via-dripping-or-micro-injection/ 
• Request samples to order in bulk.
• Make sure that there is consistency in the batches.
• Ask for safety information for all products.

c) Curing, troubleshooting, and common problems

During the curing process, liquid PVC becomes a solid patch. The time and temperature will vary, depending upon the material being used; never assume a length of time or temperature, always refer to your supplier's instructions. Both under and overheating can cause patches to become soft or sticky, or can cause the patch to become discolored or curved.

Some typical issues and solutions:

• Mix bubbles slowly, rest the material and, if available, use a vacuum step.
• Poor colour mixing: Mix colours more accurately and stir well.
• Oven temperature uniformity and early removal of molds should be avoided
• If you have sticky surface, extend the curing time or check the temperature of the oven.
• Brittle patches: Ensure that the hardness of the material is not too great, and do not overheat. https://www.nist.gov/mep/additive-manufacturing3d-printing 

4. PVC Patch Maker Machine: What Machine Do You Need?

a) What machine do you need to make PVC patches?

Typical PVC Patch Maker Machine setup includes a mold making process, dispensing/filling machine and curing oven. The heart of the machine is the dispensing machine or dropping/micro-injection machine which dispenses colored liquid PVC into the mold.

Some suppliers will offer a bundle of machines and others will offer them machine by machine. For example, Dongguan Jinyu sells 12-color and 24-color dispensers as stand-alone units, while it also lists a complete PVC machine range. https://www.jinyumachinery.com/12-colors-dispensing-machine/ https://www.jinyumachinery.com/24-colors-dispensing-machine/ https://www.jinyumachinery.com/pvc-machine/ 

A typical production line would consist of a mixing machine to prepare the material, a vacuum machine to remove any air bubbles, an automated dispensing machine, a curing oven, an optional embossing machine for 3D effects and post processing equipment to trim and back the pieces.

The same supplier lists a PVC mixing machine, a PVC vacuum machine and both semi-automatic and automatic embossing machines, so you can see what each stage of a line looks like. https://www.jinyumachinery.com/pvc-mixing-machine/ https://www.jinyumachinery.com/pvc-vacuum-machine/ https://www.jinyumachinery.com/semi-automatic-embossing-machine/ https://www.jinyumachinery.com/automatic-embossing-machine/ 

There are different models of PVC Patch Maker Machine line, a typical line will consist of PVC Mixing Machine, PVC Vacuum Machine to remove air bubbles, Automated Dispensing Machine, Curing Oven, optional Embossing Machine and post-processing equipment to trim and back. Smaller operations will sometimes not make the investment in mixing and vacuum machines and begin with a dispenser and oven.

b) Setups by scale

• Hobbyist: Manual dispensing, small oven and 3D printed or bought molds. Slow speed and low output, and a good place to learn the basics.
• A small business: A semi-automatic or entry-level automatic dispenser, a dedicated oven and CNC molds. Ideal for high demand for custom orders and low quantities
• Production scale: Multi-color automatic dispenser (usually 12 colours, or greater), energy saving oven, mixing machines and energy saving vacuum machine, and special finishing units. Designed to withstand high production and scale.
• Determine your level by making an estimate of the number of patches you intend to do per week, the number of colours you need for your designs and the amount of time you can devote to practical work.

c) What kind of machine do I need to make patches?

This will depend upon the patch type that you need. A dispensing machine and curing oven are required for PVC patches. Embroidery patches require a machine capable of embroidery. Woven patches and labels require a Jacquard loom and printed patches require a printer and heat press. Most patches also require a cutter and a heat press, which is used to apply the patch to the heat.

If you are using PVC then the setup above is used. Embroidered or woven products can be more practical to have someone else do, if you also want to provide these types of work, and you can keep PVC in-house.

5. How Much Does a Patch Making Machine Cost?

a) How much does a patch making machine cost?

The price of a PVC Patch Maker Machine can vary from few hundred dollars for an inexpensive manual machine to several thousand dollars for a complete automatic multi-color patch making machine. There's a significant diversity in supplier listings. The fully automatic 12-color dispensing machine will cost you anywhere between $4,500 and $6,500. Certain automatic dispensing machine manufacturers have their products listed at lower prices; when comparing be sure to check out the specifications, warranty and shipping terms. These are indicative prices and should be checked with suppliers for up to date prices.

Supplier listings show a wider spread. Dongguan Jinyu lists a 12-color dispenser at about $3,700 to $3,800 per set, and Dongguan Yingsida lists automatic PVC and silicone dispensers from $1,200 up to $4,900. https://www.alibaba.com/product-introduction/Jinyu-Refrigerator-Magnet-Badge-Making-Machine_1600888669802.html 

Average values according to the equipment:

• Manual or hobby dispensing tools: around $200 
• The cost of an automatic dispensing machine with a lower price range is between $1000 and a few thousand dollars.
• If you want to dispense multiple colors automatically, the multi-color fully automatic dispensing machine is about $4500 and higher.

b) What affects the price

The various types of machines are available in a vast range of prices depending on whether they are manual, semi-automatic or fully automatic.

• Automation level: The higher the level of automation, the faster the output and the more expensive it is.
• The more colors the number of color channels, the more complex the machine.
• The output speed depends on the speed of the machine, which increases as the price of the machine.
• Local brands may cost more, if they are supported, than brands direct imported.
• Longer Warranty and Support: Higher warranty and support means higher costs and lower risk.
• Real value of a package can vary by accessories included (such as molds, tools, etc. and starter materials).

However, used equipment can reduce the cost but it is important to verify the condition, availability of spares and test the equipment prior to purchase.

c) Hidden and ongoing costs

• Recurring costs include materials such as PVC, pigments and backings.
• Molds: These will generally require a new mold for each new design.
• Power is always used during production in the case of ovens and dispensing machines.
• Ventilation, shelving and safety equipment in the workspace.
• There is typically waste in early batches of training and learning time.
• Maintenance: Cleaning, Calibration and spare parts.
• Heavy equipment may be costly to ship and may have duties.

The profitability of a patch depends on the cost of your patch, the cost of the mold (one-time purchase) and how many times you will need to run it, as well as the labor, electricity and overhead costs, all of which should be calculated. Budgeting tips:

• Run a smaller test before increasing the scale.
• Have an extra parts budget.
• If you monitor waste for the first few weeks, you will be able to see this.
• Do not purchase a machine larger than the machine that you are now using.

6. Choosing the Right Setup: Buying Guide and Outsourcing

a) How to choose a PVC patch maker machine

Prior to purchasing a PVC patch maker machine, determine the quantity of patches you would like to make, the quantity of colors you will require for the designs, the space available and the budget available. Consider your technical expertise and if training and after-sales service is provided by the supplier.

When assessing suppliers use this checklist:

• Request a trial or demonstration video of the machine.
• Ask the machine to give some samples.
• Ensure that the warranty is correct and spares available.
• Inquire about training, manuals and technical support.
• Check out reviews independently and get references.
• Ensure safety and electrical certifications are in place.
• Sends confirmation of shipping, installation and import costs.

The signs of a scam are unrealistic promises, no clear support contact, no sample patches and prices that are much lower than the others and not explained.

b) New vs used vs bundled starter kits

• Full warranty and higher cost on new machines and their up-to-date features. Ideal for Companies that have regular orders.
• Used machines are cheaper, but come with support and condition problems. Best for buyers that examine and test the equipment.
• Packaged Starter Kits: Contains the core equipment, moulds and materials. Best for beginners who want simple, but may be better quality at each step by individual machines.
• A starter kit is useful when you're learning, and you'd like everything to go together. The purchase of individual machines is more logical once you have a clear understanding of the machines you need and what you want to upgrade.

c) In-house production vs outsourcing

A specialist patch manufacturer might be the better option if you're dealing with narrow customer bases, designs that are difficult to reproduce, deadlines are short, or you don't have the funds for equipment. You won't have to learn the machine and molds, or invest in them, it's all there for you by a professional supplier.

The trade-offs:

• In-house: More control, better margins at scale, more up-front cost, and a learning curve.
• Lower per-patch price for small quantities of work, no control over the quality of the work done, and less control over the start time and rapidity of the job.
• If you wish to understand demand before purchasing equipment, then ordering equipment from a supplier in small quantities is a low risk method to begin to understand the market.

d) Getting pvc patches from RushPatch

If you want to avoid all the hustle of purchasing a machine you can have a specialist patch supplier like RushPatch to purchase the patch, you can get no minimums or bulk orders and get a free mockup of your patch before it is made https://rushpatch.com/products/woven-labels-patches 

Conclusion 

A PVC Patch Maker Machine is essentially a small production system consisting of PVC liquid, moulds, a liquid dispensing machine, a curing oven and finishing tools. The price of hobby setups is in the hundreds, automatic multi-color machines cost several thousand dollars and materials, molds and maintenance will cost more. Consider volume & color requirements when making equipment decisions, request demos and samples before purchase and use outsourcing if volume testing is still underway.

Don't want the hassle of buying equipment? Get free quotes for custom PVC patches and experience a design created by the specialists.