Embroidered Badges

Zen Promotional are manufacturers of custom made embroidered badges for civil, defence and military applications. All of our badges include free digitising and delivery. We manufacture badges for emergency services including fire brigades, the Australian Defence Force, the Royal Australian Air Force and the New Zealand Navy. All of our customised Velcro badges are made of the highest quality materials and are made tough like the people who wear them.

Like an embroidered patch, embroidered badges are manufactured in the same process. People in uniform such as Police, fire brigade, ambulance and anyone in the Defence Force such as the Army, Navy and Air Force generally refer to them as a embroidered badge rather than a patch. Most of the time these badges will have special backings applied.


Preparing your Design

No matter what type of artwork you have, we will review and assess it for free and advise you on what steps need to be taken to turn it into an embroidered badge design.

Preparing your artwork and choosing the correct options for your badge is very important and will make all the difference to the overall outcome of your finished badges. By allowing us to assess your artwork, we can prepare your graphics for digitising to achieve a better result.

With a minimum order quantity of just 25 pieces and an all inclusive pricing structure , you'll find ordering badges from us to be an pleasant easy process. Simply call us on (03) 5002 0442 or (02) 9011 7057 (Mon - Fri, 9:00am - 5:30pm AEST).

Design Options

When designing your embroidered badge we are able to offer you a full range of options to complement the look, design and function of your badge. These options include metallic threads, merrowed and laser cut borders and plastic and Velcro backings.

Quality control

We take quality control very seriously. We have a multi stepped QC process to make sure that no mistakes are made in the manufacturing of your badges.

Step 1. We provide you with a digital PDF proof of your badge design with full product specifications.
Step 2. We provide you with a PDF proof of your digitising and stitch pattern. (Optional Step)
Step 3. We provide you with a scan of your pre-production sample for thread colour and design approval .
Step 4. Check patch design and colours before dispatch

100% Replacement Guarantee

We offer a 100% replacement guarantee on all of our embroidered badges. If your badges are faulty, or there is a mistake in the patch design, or if your patches are not exactly what you ordered then we will happily remake and replace your order for free. **Replacement guarantee subject to manufacturing tolerances.

Free Samples

If you would like to check out the quality of our workmanship before making a purchase, please contact us to request some free samples. Simply call us on (03) 5002 0442 or (02) 9011 7057 to order yours today.

Further Information

Are Embroidered Badges Right for me?
This mainly depends on your design and intended application. If you want the nice look of embroidery and you are willing to compromise on artwork modifications if required, then embroidered badges are most likely for you. If you have very detailed and complex artwork that cannot be easily modified without taking away major elements or the look of your design then printed patches may be your only option.

Limitation of Embroidered Badges
In relation to your artwork or design, embroidered patches do have limitations. Just like printing, embroidery has a limit to its resolution, (the number of stitches that can be laid down in 1 inch and how small we can make a stitch). We are also restrained when it comes to dealing with gradients, and they must be dealt with in a different way to a printed gradient.

Badge Resolution
When making a patch we are limited around 75tpi (threads per/inch). However different thread patterns will be used in different situations to make the badge look as close as possible to the original artwork provided. So the main thing to remember is that when you get your patches made up is not to expect a high resolution finish like a printed patch and don't expect everything to have high resolution edges because they won't. Due to the needles moving around when they are moving up and down and punching through the backing they will never strike the exact same position, so every patch will have slight differences. No two badges will be exactly the same. We are also limited to how narrow we can make a line. this is limited to about 0.75mm. Any narrower than this and we need to use a straight stitch.

Badge Gradients
When it comes to gradients (one colour blending into another) depending on where the gradient is being used, we tend to either choose to replace it with a solid colour or use 2 - 3 thread colours to try to replicate the gradient. How noticeable a change in thread colour will be will depend on how wide apart the colours are from each other. As an example shading from black to white will be very noticeable but transitioning from yellow to a slightly darker yellow will turn out much better and look closer to a printed gradient.

Badge Materials
When it comes to manufacturing a high quality product, the type of materials used will play a large part in not only the overall look and feel of the badge but also the longevity, washability and its ability to stand up to the wide variety of applications.  Zen Promotional only use the best quality threads, twills, felts & iron-on heats seals. Our polyester threads are made strong and will hold their colour for the life of your uniform. Polyester thread is our preferred thread as it will stand up to tougher treatment than Rayon. Our patches are designed to withstand commercial washing and have excellent UV resistance. Our iron-on heat seal is an imported product from the USA and has excellent adhesion compared to other cheaper heat seals. Other backings include Velcro and peel and stick self-adhesive backings.

Badge Applications
Embroidered and felt badges can be used for many applications. Their main use is for branding of clothing, such as emergency services, commercial and military uniforms, hats, work wear, sportswear, branded clothing lines, jackets and blazers. However they can also be used for branding luggage, bags or other items where a high quality logo or brand is required. It is also possible to make items such as embroidered key rings.

Ordering Process
Ordering your embroidered badges is an easy process. Simply call us on (03) 5002 0442 or (02) 9011 7057 (Mon - Fri, 9:00am - 5:30pm AEST), Visit our contact us page or simply click on the "ENQUIRE ABOUT THIS ITEM" button that you will find on every product page. Send us your phone number, the size of the badge you would like, the number of pieces you require and the backing you would like, such as sew on, iron-on heat seal, Velcro or self adhesive. It is also helpful if you can email us a copy of your artwork or design so we can give you a more accurate quote. We usually respond to 90% of enquiries within 1 hour or less during business hours. If you are after printed patches then these can be ordered directly online by clicking on the "Buy Now" button that you will find below the prices on each product information page for this product range.