Custom Ultrasonic Embossed Patches: 3D Raised Design & Cotton Filling

High-quality custom patches featuring ultrasonic embossing technology for a distinct 3D raised effect with soft cotton filling. Available with twill fabric backing and PES adhesive. Multiple edge finishes including merrowed, laser cut, or heat cut. Customizable with iron-on or sew-on attachment methods. Full customization options available for logos, patterns, sizes, shapes, materials, backings, processes, colors, and edge finishes. Ideal for clothing, hats, bags, uniforms, tactical gear, and work clothes.

Advanced Ultrasonic Embossing Technology for Premium 3D Effects
Our ultrasonic embossing process uses high-frequency vibrations to create precise, raised patterns on the patch surface. Unlike traditional embroidery or printing, ultrasonic embossing delivers clean, high-definition designs with a soft, puffy 3D texture. The technology bonds fabric layers without thread or heat damage to surrounding materials, resulting in durable, fray-resistant patches that maintain their shape and detail over time. This process is ideal for logos, lettering, and intricate patterns where depth and dimension are desired.

Soft Cotton Filling for Comfortable Puffy Texture
Each patch incorporates soft cotton filling beneath the embossed surface. This filling creates a plush, padded feel that stands out from standard flat patches. The cotton filling provides:

• Comfortable Cushioning: Gentle against fabric and skin, ideal for items worn close to the body

• Enhanced Durability: Maintains shape and loft even with repeated handling and washing

• Premium Appearance: Creates a high-end, dimensional look that conveys quality and craftsmanship

Quality Twill Fabric with PES Adhesive Backing
Crafted on durable twill fabric known for its diagonal weave pattern and exceptional strength:

• Twill Fabric Base: Provides a stable, tear-resistant foundation that holds embroidery and embossing details beautifully

• PES Adhesive (Polyester Adhesive): Thermoplastic adhesive that bonds securely when heated, offering strong initial tack and long-term holding power

• Smooth Application: Compatible with standard heat press equipment for professional results

Multiple Attachment Options for Versatile Use
Choose the attachment method that best suits your application:

• Iron-On Backing (Heat Seal): Apply at home or in production using a household iron or heat press. This backing melts to bond with fabric when heated, creating a permanent bond perfect for garments and accessories.

• Sew-On: Traditional attachment method using needle and thread. Ideal for items that require extra durability or cannot withstand heat application, such as technical fabrics, leather, or gear that will undergo heavy abrasion.

Professional Edge Finishes for Clean Appearance
Three edge finishing options available to suit different aesthetic and durability needs:

• Merrowed Edge: Overlock stitched border that wraps completely around the patch. This traditional finish provides a smooth, rounded edge that resists fraying and offers a classic, professional look commonly seen on uniform and scout patches.

• Laser Cut: Precision-cut edges using laser technology for razor-sharp, clean lines without stitching. Ideal for custom shapes and intricate silhouettes. The laser seals fabric edges to prevent fraying while delivering a modern, seamless appearance.

• Heat Cut: Thermally sealed edges that melt slightly to prevent unraveling. Provides a clean, slightly softened edge that balances durability with a lower profile than merrowed edges.

Comprehensive Customization Options
We offer complete flexibility to bring your vision to life:

Certified Quality Assurance
All patches are manufactured to meet professional quality standards. We are committed to delivering products that meet or exceed industry expectations for durability, colorfastness, and construction integrity. Certification documentation including SGS test reports is available upon request for material safety, wash durability, and lead/phthalate compliance.

Versatile Applications Across Industries
These ultrasonic embossed patches are suitable for a wide range of uses:

• Clothing: Jackets, denim, hoodies, shirts, pants, school uniforms

• Hats: Baseball caps, beanies, bucket hats, snapbacks

• Bags: Backpacks, tote bags, duffel bags, messenger bags, laptop bags

• Uniforms: Corporate uniforms, school uniforms, sports team jerseys, scout uniforms

• Tactical Gear: Military gear, law enforcement equipment, outdoor survival gear, MOLLE attachments

• Work Clothes: Construction vests, mechanic uniforms, industrial workwear, safety apparel

Production Lead Times
Efficient production scheduling to meet your timeline requirements:

Express service available for urgent orders. Production times begin after artwork approval and deposit confirmation. Shipping time varies by destination and selected carrier.

Easy Application Instructions

Iron-On (Heat Seal) Method:

1. Pre-heat iron to cotton setting (approximately 150°C / 300°F) with no steam

2. Position patch on garment with adhesive side down

3. Cover patch with thin cotton cloth to protect surface

4. Apply firm pressure with iron for 30–45 seconds

5. Allow to cool completely before checking adhesion

6. For heat press: 150°C / 300°F, medium pressure, 12–15 seconds

Sew-On Method:

1. Position patch on garment

2. Pin or temporarily adhere using fabric glue stick

3. Using matching thread, stitch around the inner edge of merrowed border or along laser cut perimeter

4. Use straight stitch or zigzag stitch for secure attachment

5. Tie off threads on reverse side

Wash Care Instructions
To maximize patch longevity:

• Heat-Sealed Patches: Machine wash cold, gentle cycle; turn garment inside out; do not bleach; air dry or tumble dry low; do not dry clean

• Sew-On Patches: Machine wash warm; gentle cycle recommended; turn garment inside out; tumble dry low

• For both attachment types: Avoid direct ironing on the patch surface; use pressing cloth if ironing over patch is necessary

Product Specifications

• Technology: Ultrasonic embossing

• Filling: Soft cotton filling for 3D puffy effect

• Base Fabric: Twill fabric (diagonal weave)

• Adhesive: PES (polyester adhesive) for iron-on option

• Edge Finishes: Merrowed edge, laser cut, or heat cut

• Attachment Methods: Iron-on (heat seal) or sew-on

• Customization: Full range including logo, size, shape, material, backing, process, color, edge finish, packaging

• Quality Assurance: SGS testing available upon request

• Applications: Clothing, hats, bags, uniforms, tactical gear, work clothes

Why Choose Our Ultrasonic Embossed Patches?

• Superior Dimensionality: Ultrasonic embossing creates deeper, more defined textures than traditional heat pressing

• Soft Hand Feel: Cotton filling eliminates the hard, plastic feel of some puffy patches

• Fray-Resistant Edges: Laser and heat cut options seal fabric edges preventing unraveling

• Fast Turnaround: Efficient production with clear lead times by quantity

• Complete Customization: No minimum restrictions on design complexity

• Professional Results: Suitable for retail, promotional, uniform, and commercial applications

Ordering Process

1. Submit artwork (vector files such as AI, EPS, CDR, or high-resolution PNG/JPG)

2. Receive digital proof and quote

3. Approve artwork and confirm order details

4. Production begins (timeline based on quantity)

5. Quality inspection and packaging

6. Shipping with tracking information provided