Embroidered patches are available in a variety of sizes, ranging from about 2' to 7' or more, depending on the needs of the group involved. Patches can easily be obtained from reputable sellers online, such as Patches4Less.com.
Designs can be as simple or as elaborate as you wish, with several backing twill colors available, and a wide selection of thread colors, including neon and metallic shades, for a color palette ranging from mild to wild.
Borders of embroidered patches are readily available in two common types, hot cut or merrowed. The hot cut border is ideal for custom-shaped patches, and when used with an iron-on backing, enables the iron-on adhesive to extend all the way to the edge of the patch. A merrowed border is the industry standard, a border of thread hand-stitched all the way around the patch. This creates a traditional patch appearance, and serves to visually separate the twill of the patch from the garment onto which it is applied.
A number of backing options in addition to the standard twill backing are available for embroidered patches, with each serving a particular need. Velcro backings, for example, are popular with military units because they allow the patches to be removed as necessary and replaced later. Plastic backing is very common on many patches, because it adds sturdiness and overall quality to the patch design. Iron-on backing can be used alone to hold patches in place through about 20 to 25 washings, or can be used to hold a patch steady to enable it to be sewn into place. Tape backing is perfect for temporary patches for special events.