Welcome to Patchwork Designs, Incorporated.


We begin with an image, idea, photo, or sometimes a hand drawn item from a child. For the Spain images, we had a client that visited and provided us photos for inspiration	We create graphic images from the design that we will use on the patch.

Using color, depth, and a little of our imagination, a unique 3-D effect is created on a patch. If it is a custom design then the image is sent to the customer for review. During your review, you should change any colors or image placement prior to digitizing the patch on the computer	Design is finalized. Thread colors and twill color is chosen. Up to NINE colors of thread are chosen, sometimes more. We have satin twills, glow in the dark threads, metallic threads, and cotton twill

Colors are assigned to the patch by drawing lines on the image and noting the colors. At this point we can not change color choices without re-digitizing the patch again.	The colors are then digitzied into the computer and saved on a disc for easy reorders. The customer will soon be sent a sew-out sample via email to check for mis-spelled words.


The spools of thread are pulled from the shelves and threaded on the machines according to the color choices.	The twill (background material) is loaded on the machine.

The disk is loaded on the computer attached to the machine. The correct patch and quantity is produced.	The machines start creating the patches on the large piece of fabric. The machines are automated but watched closely for broken needles or thread as that could be costly if it was not detected.

Strips of patches are placed upside down under the press to adhere the backing to it. [PVC, plastic sew-on backing, IRON-ON, or SELF ADHESIVE]	The sewn patches are removed from the machine. They are carefully cut in rows.

Each patch is cut apart so the edge can be placed on the patch.	The merrow edgeis placed on the patch

The patches are counted and checked in quality control for errors. Then they are bundled in sleeves of 100's.	Then the patch is entered into inventory, invoiced, payment received, and shipped to you the customer.

Why does it cost more to produce 50 patches, rather than 100 patches?
The typical piece of twill that loads on the machine holds about 100 patches. The remainder of the twill has to be cut away and tossed. We also have to complete all the same steps for 50 patches or 1,000 patches.
Can we take a tour of your factory?
Sorry, we can not allow non-employees in the factory due to safety reasons. Though we have provided you with the steps above, so everyone can view the process online and understand better how a patch is created.