Patch Size Calculator
Work out your patch's trade size, area and per-order totals.
Quick answer: Custom patch pricing is based on trade size: (width + height) divided by 2. A 4x2 inch rectangular patch and a 3-inch circle are both '3-inch patches' for pricing. The most popular sizes are 3-3.5 inches for jackets and 2-2.5 inches for hats. Calculate any shape below.
Patch pricing across the industry is based on 'trade size' — the width plus height divided by two. A 3×2 inch patch is a 2.5" patch for pricing. This calculator gives you the trade size, true area and per-order totals for any shape and unit, so you can compare quotes on equal footing.
It also flags the details that move a patch quote most: size band, quantity break, backing type and embroidery coverage.
How it works
- Pick a shape (circle, square, rectangle or oval) and enter dimensions in inches, cm or mm.
- Enter your quantity to see total stitched area for the run.
- Use the trade size to compare vendor pricing — then request an exact DigitEMB quote.
Good to know
- This calculates geometry, not price — real patch pricing depends on embroidery coverage, backing, border type and quantity, which is why serious vendors quote from your actual artwork.
Frequently asked questions
How is patch size measured for pricing?
The industry convention is (width + height) ÷ 2. A 4×2 inch rectangle and a 3-inch circle are both '3-inch patches' for pricing purposes. This tool calculates it for any shape.
What's the most popular custom patch size?
3 to 3.5 inches is the sweet spot for jackets, workwear and morale patches. Hat patches usually run 2–2.5 inches; large back patches run 8–12 inches.
Which backing should I choose?
Iron-on for one-time application to cotton garments, sew-on for maximum durability and washability, Velcro (hook-and-loop) for tactical and removable patches, and adhesive only for temporary use.
How many patches do I need to order?
DigitEMB has low minimums, and per-patch price drops significantly at quantity breaks (typically 50, 100, 200, 500). If you're near a break, stepping up often costs little extra total.