To measure a patch, lay it flat and measure straight across at its widest point for the width, then top to bottom at its tallest point for the height, including the border. Write both down in inches, for example 3.5 in x 2.25 in (89 x 57 mm). For an irregular or die-cut shape, measure the smallest rectangle the whole patch would fit inside. That pair of numbers is what a patch maker needs to quote and produce your patch.
Below is the method in more detail, how factories turn those two numbers into a size for pricing, and how to work out the right size when you are designing a new patch rather than copying one.
What you need and how to set up
Use a rigid steel or plastic ruler, not a soft tape measure. Tape measures curve and stretch, and a sixteenth of an inch matters on a small patch. Work on a flat table with good light.
- A rigid ruler marked in inches, ideally with 1/16 in divisions, and millimetres if it has them.
- A flat, hard surface. If the patch is sewn on, measure it on the garment laid flat, or remove it first.
- A pen and paper, or your phone, to write the numbers down straight away.
- A photo of the patch taken square on, with the ruler in the shot, if you are sending it with a quote request.
If the patch has curled or been washed many times, press it gently flat with your hand. Do not stretch it. An old patch that has shrunk a little is still the best guide to what you need, and we can adjust slightly if you tell us the original size.
Measuring width and height
Place the ruler across the patch at its widest point, from the outside edge of the border on one side to the outside edge on the other. That is the width. Then measure from the very top to the very bottom at the tallest point. That is the height. Always measure the whole patch, border included. A merrowed border adds a little to every side, and leaving it out makes the quoted patch come back slightly smaller than the one you held.
Round to the nearest 1/8 in (about 3 mm). Factories work in inches, and a quote will usually show sizes such as 3 in, 3.5 in or 4.25 in. If you prefer millimetres, give both: 4 in (102 mm).
Round and oval patches
For a circle, measure the diameter, edge to edge straight through the center. Width and height are the same. For an oval, measure the long axis and the short axis separately. Do not measure around the edge: the circumference is not used for patch sizing.
Measuring die-cut and irregular shapes
A die-cut patch follows the outline of the artwork: a mascot, a state outline, a bike or a badge with points. Picture the smallest rectangle the patch would fit inside, and measure that box. The width runs from the furthest point on the left to the furthest point on the right. The height runs from the highest point to the lowest point. The two points you measure from do not need to line up with each other.
Shields are a common case. Measure the width across the widest part, usually near the top, and the height from the top edge to the bottom point. For a star or a badge with rays, measure from tip to tip. For a patch with a hanging loop or a tab, tell us whether your measurement includes it, since some people measure the main body only.
How factories turn two numbers into a patch size
Many patch makers in the industry describe size as a single number: the average of width and height. Add the two dimensions and divide by two. A patch that is 3 in wide and 4 in tall is a 3.5 in patch. A 2 in x 5 in name tape is also a 3.5 in patch by this measure, even though it looks very different. As a rule of thumb, this single size is what drives the price, along with stitch coverage, quantity, border and backing.
Not every supplier states size the same way, so always look at the width and height written on the quote and the proof, not just a single size label. When you request a quote from us, give width and height and we will confirm the size on the quote. For how size feeds into cost, see what drives the price of custom patches.
| Patch | Width x height | Average size |
|---|---|---|
| Round cap patch | 2.5 in x 2.5 in (64 x 64 mm) | 2.5 in |
| Shield shoulder patch | 3.5 in x 4.5 in (89 x 114 mm) | 4 in |
| Name tape | 4 in x 1 in (102 x 25 mm) | 2.5 in |
| Rectangular chest logo | 3.5 in x 2 in (89 x 51 mm) | 2.75 in |
| Large back patch | 10 in x 10 in (254 x 254 mm) | 10 in |
Sizing a new patch for a garment
If you are designing from scratch, measure the space the patch will sit in rather than an old patch. Put the garment on a hanger or lay it flat and measure the area available.
- Cap front: measure the height of the front panel from just above the brim to where the crown starts to curve back. Most cap patches sit at roughly 2 to 2.5 in (51 to 64 mm) tall, because the panel curves above that.
- Sleeve: measure across the upper sleeve below the shoulder seam with the sleeve flat. Shoulder patches commonly run about 3 to 4.5 in (76 to 114 mm).
- Left chest: measure from the placket or zipper to the side seam at chest height. A chest logo of about 3 to 4 in (76 to 102 mm) wide is typical.
- Jacket back: measure across the shoulder blades between the sleeve seams. Back patches often run 8 to 12 in (203 to 305 mm).
A useful trick is to cut a paper rectangle to your planned size, tape it in place and look at it from a few steps away. You will see quickly whether it is too large for a cap or too small for a jacket back. Our patch size guide gives typical sizes for each placement, and the size guide on the patches page shows them at a glance.
Check that your detail fits the size
Once you have a size, check your smallest lettering against it. As a general guide, embroidered text needs about 1/4 in (6 mm) of letter height to read clearly, and lines under about 1 mm do not stitch well. A design that reads well at 4 in can lose its small text at 2.5 in. If you need to stay small, a woven patch holds finer detail than embroidery. You can also upload your art to the free Patch Studio, set the width and height, and see it on a jacket or cap before you quote.
Sending measurements with your quote request
Give us the width and height in inches, say whether the border is included, and add a square-on photo with a ruler in view. If you are copying an existing patch, our guide to recreating an existing patch lists the rest of the details to send. Then request a quote with the quantity, backing and in-hands date. The quote returns in 2 to 3 business days, and the proof shows the exact dimensions before anything is made.
