The Difference between Woven and Embroidered Patches
The branding patch is manufactured in two forms: Woven and Embroidered.
Custom woven patches in general may be circular, square, or laser cut into any specific shape requested. Patches are permanent fixtures to garments---they are usually attached to the outside of the fabric and not intended to be cut off or removed easily like regular sewing labels can. Oftentimes, they are conspicuous and contain emblems, logos, and written information.
Custom woven patches have higher definition (resolution) of the lettering and logo edges than embroidered. They are usually 30-50% cheaper to produce and have a quicker turnaround time. They are flatter and easier to sew or iron on a piece of fabric than embroidered patches.
A "laser cut" or "die cut" woven patch is cut into a shape other than a square, such as an oval or stars shapes. Because oven patches are larger than regular woven labels, more logo or lettering detail (resolution) can be produced. A larger woven area means greater graphic detail capabilities.
Custom embroidered patches have a three-dimensional “lift” to the fabric due to the density of the stitched thick threads. Embroidered stitching allows for a classy look, but is not the best choice for capturing high resolution detail, containing costs, or with working with very tight production schedules. In essence, they are more expensive and take longer to manufacture.
You can assess your graphic requirements and budget and determine which is the best choice for your project. If cost is a primary concern, then consider the laser cut woven patches.
If containing costs is less of a concern and you want a three-dimensional texture (or life) to your patch, then embroidery is the way to go.