Woven and embroidered patches can be used interchangably in the majority of cases. The design itself will usually dictate which type of patch is more ideal. Read on to see which patch is better for your particular needs.
Block fonts in capital letters of at least 1/4 of an inch high work best for embroidery. Going below these requirements compromises legibility.
Thinner threads allow for more freedom of design. Lowcase and even script lettering are usually legible, and text can be half the size it can be with embroidery.
Because threads can be overlayed in multiple levels with embroidery, a blending effect can be acheived.
Smatterings of different colored threads can be compacted into small spaces, giving the illusion of gradiation.
Thick threads allow for less detail than woven patches, however, different stitch directions and embroidery percentages can produce certain special effects not possible in woven patches.
Woven patches use thinner threads than embroidered patches, which allows for more fine detail. In addition, the weaving process is much tighter, allowing for more detail to be packed into a smaller space.
Because threads are stitched onto a base fabric, embroidered patches can acheive different levels of dimension. Dimension can also be achieved by controlling the percentage of the fabric that is covered with thread.
Woven patches have a single level of thread, and therefore have a flatter look than embroidered patches. Because no base facric is used, the patches themselves aren't as thick as embroidered patches.
Thick threads are stitched into a cotton twill background fabric as a base, thus giving these greater stability and longevity than woven patches.
Theads are thinner and woven together without a base fabric to be anchored to. Their extremely tight weave helps with stability, however, embroidered patches have the edge here.
The decision to go with an embroidered patch or a woven patch is entirely up to you. If your design has a lot of small detail, woven is likely a better choice. If you are looking for a more rugged patch that will withstand a harsh environment, consider an emboridered patch.