Custom 3D Embroidered Patches

3D embroidered patches use a layer of foam underneath the stitching to create a raised, dimensional effect. The thread is stitched over the foam, giving letters and design elements a bold, sculpted look that literally stands out from the patch surface. It's the same technique used on premium hat embroidery.

Yes — all of our custom 3D embroidered patches are made in-house at our Canadian production facility. Button Bros has over 50 years of manufacturing experience in Canada.

Bold text, thick lettering, and large graphic elements work best. The foam needs enough surface area to create the raised effect — elements should be at least 3mm wide. Fine details, thin outlines, and small text are better suited to standard flat embroidery.

We use high-density embroidery foam that creates approximately 2–3mm of raised height. The foam is completely encased by the thread stitching, so you only see and feel the embroidered surface — not the foam itself.

Absolutely — 3D patches are one of the most popular ways to customize hats and caps. The raised dimensional look gives hats a premium, professional finish. Heat-applied backing works great for structured caps, and our sizes from 3" to 5" are ideal for hat fronts.

We offer three backing options: Heat applied (iron-on) — bonds with a heat press or household iron. Peel & stick — adhesive backing for temporary placement or displays. Sew-on — designed to be stitched onto fabric for a permanent hold.

Production takes 2–3 business days from proof approval. Add standard shipping (3–7 business days within Canada) and most orders arrive within a week. Express shipping is available at checkout.

The minimum order is 10 pieces. Volume pricing kicks in automatically — the more you order, the more you save per patch.