D&D Creative Co.

Embroidery · East Tennessee

Custom embroidered patches.

Stitched in-house and finished with a merrowed border, in any shape your logo calls for. Choose sew-on, iron-on, or hook-and-loop backing, then put them on caps, jackets, work shirts, and bags.

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Custom embroidered patch with a merrowed border sewn onto a hat

Shapes and finishing

Merrowed border

The wrapped overlock edge that seals the twill and gives the patch its raised outline. Best on circles, ovals, shields, rectangles, and other clean geometric shapes.

Die-cut and custom shapes

When the logo outline isn't a simple shape, the edge is stitched and cut to follow the artwork itself — mascots, script wordmarks, crests, and irregular silhouettes.

Coverage and twill

Full-coverage patches are stitched edge to edge; partial-coverage patches leave the twill exposed as a background color. Both change the look and the stitch count.

Embroidery machine stitching a custom patch design

Backing options

  • Sew-on

    A plain back stitched down by hand or machine. The most durable option and the standard for uniforms, jackets, and hats that see hard use.

  • Iron-on heat seal

    A heat-activated film on the back for quick application to cotton and cotton blends. Fast and clean; we still recommend tacking edges down on high-wear garments.

  • Hook-and-loop

    For patches that need to come off — tactical panels, name tapes, rotating team or sponsor patches. Loop side can be added to the garment as well.

  • Applied by us

    Send the garments or let us source them, and we'll sew the patches on so the whole order arrives finished.

Edge finishes

Border types

The border is what separates a patch that looks manufactured from one that looks homemade. Merrowed is our default; the others exist for shapes a merrow machine cannot follow.

Merrowed border

Our default

A raised overlock thread wrapped around the entire edge. Only works on simple shapes — circle, oval, rectangle, shield — because the machine needs a continuous curve. Toughest edge you can put on a patch and the classic look on a cap.

Hot-cut border

Complex shapes

The patch is cut with a heated blade that seals the twill, then finished with a tight satin stitch. Use it when your logo outline is too intricate for merrowing.

Laser-cut border

Fine detail

Laser cutting follows the artwork exactly for sharp points, thin letters, and cut-out negative space. Cleanest option for custom silhouettes.

Die-cut / no visible edge

Flat finish

The border stitch sits flush with the patch face instead of standing proud. Lower profile under a jacket panel or on a soft, unstructured hat.

Patch sizing chart

Patch size is measured as the average of width and height. Use this as a starting point — send us the artwork and we'll tell you the smallest size your logo stays readable at.

SizeTypical useDetail it holds
2"Cap front (unstructured), sleeve, beanie cuffIcon plus one short word. Avoid taglines.
2.5"Left chest, polo, cap frontLogo mark with a wordmark under it.
3"Trucker cap front, jacket chestMost business logos land here — name, icon, and an est. date.
3.5"Flat-bill cap front, work shirt chestRoom for a second line of text or a state outline.
4"Jacket chest, bag panelFull lockup with a tagline stays legible.
6"–8"Jacket back, hoodie back, banner patchesDetailed crests, rockers, and multi-line text.
10"–12"Full jacket back panelAnything. Stitch counts get high, so quantity pricing matters more here.
Embroidered patch with a merrowed border sewn onto a structured cap front

Patches on hats

A patch on a cap wears differently than direct embroidery. The patch is stitched flat to the front panel, so the artwork keeps its shape on a soft crown and you can run the same patch across trucker, rope, and unstructured styles without re-digitizing for each fabric.

  • Trucker caps — a 3" merrowed patch centered on the structured front is the most-ordered combination in the shop.
  • Rope and foam-front hats — go slightly larger, up to 3.5", since the tall front panel makes a small patch look lost.
  • Unstructured dad hats — keep it to 2.5" and use a flatter border so the patch moves with the soft crown.
  • Beanies — rectangles on the cuff only; the knit will not hold a large or complex shape flat.
Leather patch hats →Direct embroidered hats →

Artwork and digitizing

Send your files

Vector art is ideal (AI, EPS, SVG, PDF); a high-resolution PNG works as well. Include thread or brand colors you need matched, plus the finished patch size.

We digitize it

Your logo is rebuilt as stitch paths with the right underlay, density, and edge treatment for a patch. One-time step per design, reused on every reorder.

Size drives detail

A 3-inch patch holds far more than a 2-inch one. We'll tell you where text or fine lines will close up and either scale the patch or simplify the detail before running it.

Embroidered patch or leather patch?

An embroidered patch carries color and thread texture, holds a hard edge, and works on any garment. It's the right call for multi-color logos, crests, and anything too detailed to stitch directly into a cap panel.

A laser-engraved leather patch is a single-tone, rustic look with crisp fine detail — a different aesthetic on the same hats. Direct embroidery skips the patch entirely and is the cleanest finish for simple wordmarks.

Custom leather patch hats →Custom embroidered hats →
Leather patch hat beside an embroidered patch cap

Team, business, and club runs

Company uniforms, crew and service patches, church and school groups, clubs, tournaments, and event merch. Digitizing is done once, so reorders come out identical to the first batch. Tell us the size, shape, backing, and quantity and we'll come back with a firm number and a date.

Get pricing for your run

Common questions

What is a merrowed border?

It's the wrapped overlock stitch around the outside edge of a patch. It seals the twill so it can't fray and gives the patch its finished, raised outline. It suits circles, ovals, shields, and rectangles.

What backing options do you offer?

Sew-on (plain back), iron-on heat-seal for quick application on cotton and blends, and hook-and-loop for patches that need to come on and off. Tell us where the patch is going and we'll recommend one.

Is there a minimum order?

No hard minimum. We run small batches and full production runs. Digitizing is a one-time step per design, so per-patch cost drops as the quantity goes up.

What artwork do you need?

Vector art (AI, EPS, SVG, PDF) is best; a high-resolution PNG works too. We digitize your logo into stitch paths before production and simplify anything that won't hold at patch size.

How small can the text be?

Thread has a physical limit. Very thin lines and tiny lettering close up when stitched, so we either scale the patch up or rebuild the detail. We'll flag it before anything runs.

Can you sew the patches onto hats or garments?

Yes. We can ship loose patches, or apply them to caps, jackets, shirts, and bags as part of the same order.

Service areas

Custom Embroidery across East Tennessee

We produce in Jefferson City and Johnson City and ship or deliver throughout the region. Pick your town for local details, turnaround, and pickup options.

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