Embroidery coverage refers to how much of a patch’s surface is stitched with thread. It’s usually expressed as a percentage 50%, 75%, or 100% and this value directly affects the look, feel, and cost of the patch.
When we say “100% embroidery,” we’re talking about a patch that has its entire surface covered with stitching. On the other hand, 50% coverage means part of the fabric, often twill, is still visible. Understanding embroidery coverage helps you make informed decisions about design, detail, and pricing.
Why Embroidery Coverage Matters
Embroidery coverage isn’t just a design decision it impacts durability, aesthetics, and budget. High coverage adds more thread, which often enhances the richness and texture of a patch. In my experience working with clients, patches with greater coverage are seen as higher quality.
They feel more substantial and have a premium look. However, more thread means more cost. Choosing the right coverage level ensures your patch meets both your visual expectations and your budget. It’s a critical part of patch customization.
Levels of Embroidery Coverage Explained
Embroidery coverage typically comes in three main levels: 50%, 75%, and 100%. Each level offers distinct benefits depending on your design needs, budget, and branding goals. Let’s look at each in more detail.
50% Embroidery Coverage
This is the most budget-friendly option and perfect for simple designs. Only half of the patch surface is stitched, leaving the twill fabric exposed in many areas. I’ve often recommended 50% coverage for clients who want clear text or minimal graphics.
It’s ideal when contrast between thread and background is part of the design appeal. This coverage allows for faster production and lower costs, making it great for bulk orders. It’s practical, especially for straightforward logos or bold text-based designs.
75% Embroidery Coverage
75% coverage is a balanced option that allows for more detail without fully covering the fabric. This middle ground is great for slightly complex logos or mixed design elements. I’ve seen this used effectively for patches that require both text and moderate graphics.
The patch still shows some fabric, but the embroidery is prominent enough to draw attention. It feels richer than 50% but doesn’t reach the density or price of full coverage. This level offers excellent value and visual appeal.
100% Embroidery Coverage
This is the premium option. Every inch of the patch is filled with stitching. It allows for high detail, bold colors, and an incredibly textured feel. I always suggest 100% embroidery when the design involves shading, gradients, or intricate logos.
It elevates the patch, making it ideal for branding, uniforms, and collector editions. Yes, it’s more expensive, but it delivers a refined, professional finish. If your design needs maximum impact and detail, this is the way to go.
Embroidery Coverage and Patch Pricing
The percentage of embroidery coverage directly impacts the cost of production. More stitching means more thread, time, and machine work. A patch with 100% coverage is more labor-intensive and will naturally cost more than a 50% embroidered patch.
In pricing discussions, I always remind clients that the coverage level affects not only aesthetics but also their overall budget. Digitization and thread color counts also play a role. When balancing design and cost, embroidery coverage is a key factor to consider.
Comparing Embroidery Coverage with Other Patch Types
Embroidery coverage matters most in embroidered patches, but other patch types offer different strengths. PVC patches, for example, aren’t stitched they’re molded, allowing for intricate 3D effects. Woven patches use thin thread to capture high detail without the raised texture.
Printed patches use dye sublimation to show photo-like detail, regardless of coverage. Embroidered patches, though, offer that unique stitched feel and premium texture. The level of embroidery coverage gives you control over how bold or subtle your design appears.
Design Considerations Based on Embroidery Coverage
Design choices must align with your coverage level. At 50%, you need high-contrast colors so the background twill stands out and complements the thread. For 75%, you can experiment with slightly more complex layouts.
Full coverage lets you go wild gradients, fine lines, and custom thread work shine best here. One often-overlooked detail is how embroidery direction reflects light. That can add depth to a fully covered patch. So when patch designing, remember: embroidery coverage is not just a cost it’s a creative constraint and opportunity.
Choosing the Right Coverage for Your Patch
To choose the right embroidery coverage, start by evaluating your design complexity. Simple text? Go for 50%. Need clarity and moderate detail? 75% hits the sweet spot. Want to showcase a detailed logo with layered colors? 100% is your best bet.
In my opinion, coverage is about balance what’s visually necessary versus what’s financially sensible. Remember, the same design can feel very different at each level. Consider your use case, whether it’s for branding, giveaways, or uniforms, and make your choice accordingly.
Final Thoughts: Balancing Art, Cost & Function
Embroidery coverage is more than a technical term. It shapes how your patch looks, feels, and fits your budget. Whether you’re creating patches for fashion, branding, or personal use, the right coverage can bring your vision to life.
I’ve seen clients regret going too low or overspending on unnecessary detail. My advice? Start with your design goals. Then consider your budget. And always ask your patch provider for samples or digital proof / digitizing of patch before deciding. With the right embroidery coverage, your patch can truly stand out.
FAQs
How is embroidery coverage calculated?
It’s based on the percentage of the patch area covered by thread versus exposed twill.
Is more embroidery always better?
Not always. It depends on the design and purpose. Sometimes less coverage gives a cleaner look.
Can you mix coverage levels?
Not on one patch. But you can use different levels for different patches in a collection to save cost or create visual contrast.