Custom PVC Patches in San Diego

We build custom PVC patches that outlast the gear they’re attached to. These are waterproof, 3D-sculpted rubber emblems designed for tactical vests, trucker hats, and outdoor crews.

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  • Waterproof, 3D-sculpted rubber
  • Won’t fade in the sun
  • Won’t fray in the wash
  • Scrubs clean after a day in the dirt
White rectangular PVC patch with a blue dragon logo and Dragon Lore Tours text.

Why San Diego Brands Choose PVC Patches

Living in San Diego means dealing with two things: high UV exposure and the salt air.

Built for Coastal Weather

Thread rots in salt air. Rubber doesn’t.

Flexible Rubber

It bends with your hat or jacket. It won’t crack in the sun.

Bold Colors

We inject colored liquid rubber into the mold. It stays sharp and readable long after embroidery fades.

Easy to Clean

Get mud, grease, or beer on it? Just wipe it down. Try doing that with a stitched patch.

What Makes PVC Different From Thread Patches

You need to understand the physics of the material. Embroidery is thread stitched onto fabric. PVC is a solid piece of molded soft rubber.

PVC vs. Embroidered

  • No Loose Threads

    There’s nothing to snag on a branch or a wire fence. Solid construction.

  • Fully Waterproof

    Embroidery acts like a sponge. PVC acts like a raincoat.

  • 3D Sculpted Look

    We can raise elements of your logo to create actual physical depth you can feel.

PVC vs. Woven

  • Better for Bold Logos

    Woven is for tiny details. PVC is for impact and readability at a distance.

  • Rubber Texture

    It has a matte, tactical finish that matches modern tactical gear.

  • Ideal for Outdoor Use

    If you’re surfing in Ocean Beach or hiking Torrey Pines, go with PVC.

Popular Uses Around San Diego

From the flight line to the coastline, PVC is the choice for durability.

Military & Tactical

Miramar / Coronado
The Gear: Name tapes, morale patches, and unit insignia.
Why: Plate carriers get dirty. PVC cleans up with a hose. We use non-IR reflective colors when the spec calls for it.

Surf, Skate & Outdoor

Encinitas / Carlsbad
The Gear: Hat brands and backpack badges.
Why: Salt water ruins standard patches. PVC handles the morning surf check without falling apart.

Businesses & Events

Pacific Beach / Yacht Club
The Gear: Branding for gyms and boat crews.
Why: Withstands sweat and water. Signals ‘high performance’ better than a fuzzy cloth patch.

Schools & Teams

County-Wide
The Gear: Spirit wear and bag tags.
Why: Kids destroy gear. Rubber armor survives the locker room.

PVC Patch Styles You Can Order

From flat corporate branding to sculpted 3D mascots.

Crisp Edges Tactical PVC patch featuring a topographic map design showing distinct flat layers of molded rubber.

2D PVC Patches

Think of this like a topographic map with flat layers. The background is one level, the text is the next level up. It has hard, crisp edges. Best for clean corporate logos.

Sculpted Custom 3D PVC mascot patch featuring an aggressive wolf head design with distinct rubber layers.

3D PVC Patches

We round the edges and sculpt the rubber. It looks like a mini-statue. Ideal for mascots or character logos where you want realistic contours.

Night Ops Side-by-side comparison of a custom PVC spider patch in normal light versus glowing phosphorescent green in the dark.

Glow / Reflective

We mix phosphorescent powder into the liquid rubber. It glows in the dark. Mandatory for safety gear or night-ops tactical patches.

Backing Options for PVC Patches

Velcro® Hook & Loop

? The industry standard.
We sew the Hook side onto the back of the rubber.
Perfect for swapping patches on tactical vests or hats.
PVC patch with Velcro backing

Sew-On (Channel)

? We mold a “sewing channel” (a thin groove) around the edge.
You stitch through that groove.
The only permanent way to attach rubber to a uniform.
Macro close-up of a tactical PVC patch corner showing the recessed sewing channel groove designed for needle stitching.

Adhesive (Sticker)

? 3M Peel-and-stick.
Okay for a one-day trade show.
Don’t expect it to last on a jacket.
Rear view of a custom PVC patch with white wax paper being peeled back to reveal the sticky 3M adhesive layer.

Magnetic & Pin

? We embed a magnet inside the rubber.
Great for preventing holes in expensive waterproof jackets.
Back side of a custom wolf head PVC patch showing two strong circular magnets embedded flush into the rubber.

⚠ Factory Insight: The “Glue” Myth

I see this mistake all the time. People ask for “Iron-On” PVC patches. Don’t do it. PVC is heavy. It’s a chunk of rubber. Iron-on glue isn’t strong enough to hold that weight against gravity, especially in San Diego heat. The rubber absorbs the heat from the iron and can warp before the glue melts.

The Fix: If you want it permanent, sew it on. If you want it removable, use Velcro. Forget the glue.

How Pricing Works

PVC pricing is different from embroidery. There’s a hardware cost involved.

What Affects Cost

The Mold

Before we make a single patch, we have to CNC mill a metal mold. That’s a one-time setup fee. Once you pay it, we keep the mold on the shelf for your re-orders.

Size

More rubber material equals higher cost.

Color Count

We inject the colors into the mold by hand using syringes. If your design has 8 colors, that’s 8 manual steps per patch.

2D vs 3D

3D sculpting takes longer to mill and inject.

Typical Order Ranges

Because of the mold fee, ordering 10 patches doesn’t make financial sense. The cost per unit is astronomical.

The Sweet Spot: Start at 50 or 100 pieces. That’s where the mold fee gets diluted, and the unit price drops to a reasonable level.

10 Qty
50 Qty
500 Qty

Production & Turnaround in San Diego

We don’t rush the cooling process. If we pull the rubber too early, it warps.

Step 01

Proofing

We send a digital mockup first. It shows the “levels” of the design—what’s raised, what’s recessed, and exactly what color goes where.

Step 02

Production

Mold Creation: We cut the metal block.
Injection: We fill the mold with liquid PVC.
Baking: It goes into the oven to cure.
Quality Check: We inspect for air bubbles or color bleeding.

Step 03

Delivery

We ship via UPS/FedEx daily. Whether you’re in Chula Vista or Escondido, standard ground shipping gets it there in a day.

Designing Your PVC Patch

Rubber isn’t ink. It has physical limitations.

Best Artwork Types

Vector art (.AI or .EPS) is mandatory. We drive the CNC machines with mathematical lines, not pixels. Bold lines and thick text work best.

Color Matching

We match to Pantone (PMS) codes. Since we mix the liquid rubber ourselves, the color accuracy is dead-on. It doesn’t rely on available thread stock.

Size Tips

Hat Patches:

Stick to 2.25″ tall max. Any taller and it won’t bend correctly on the forehead of a trucker hat.

Readability:

Keep text above 8pt. If it’s smaller, the rubber tends to merge together during the bake.

Why Order From Us

Real Support

You’re talking to people who know the difference between a 2D layer and a 3D sculpt. We catch errors before the mold is cut.

Quality Control

PVC can have issues with “bleeding”—where one color runs into another. If we see that, we scrap it. You don’t pay for our mistakes.

San Diego Focus

We know the local market. From the breweries in North Park to the squadrons at North Island, we know what sells and what meets regulation.

The Ordering Process

  1. 01

    Send Your Logo

    Email us your vector file.

  2. 02

    Approve the Proof

    Check the 2D/3D levels in the mockup.

  3. 03

    Production Begins

    We mill the mold and inject the rubber.

  4. 04

    Delivered to Your Door

    Boxed and shipped.

Get Your Free Quote for PVC Patches

Stop guessing at prices. Send us your art and specs, and we will give you an exact cost per unit based on thread count and coverage.

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Frequently Asked Questions

Are PVC patches waterproof and salt-resistant?

Yes. 100%. It’s rubber. Salt water, mud, blood, and beer wash right off. They will outlast the garment they’re attached to.

What size works best for trucker hats?

Standard is roughly 2.5″ wide x 1.5″ tall or a 2.25″ circle. Size Tip: Don’t go wider than 4 inches or it won’t curve around the hat panel.

Can PVC patches be sewn onto uniforms?

Yes. We mold a “sewing channel” (a thin recessed groove) around the edge. Your needle goes through that thin rubber easily.

How durable are Velcro PVC patches?

Extremely. We sew the hook backing onto the rubber using a heavy-duty stitch. The glue bond is strong, but the stitch locks it in.

What is the minimum order quantity?

50 pieces. We can do less, but the mold fee makes it expensive. 50 is the break-even point for most budgets.

Can you match my brand colors?

Yes. Give us your Pantone (PMS) code, and we mix the pigment into the clear rubber base.

What is the difference between 2D and 3D PVC?

2D has flat layers with sharp edges (like a layered cake). 3D has rounded, sculpted edges (like a statue).

Do PVC patches fade in San Diego sun?

No. The pigment is mixed through the material, not printed on top. It holds up to UV exposure better than thread.

Can I reorder the same mold later?

Yes. You pay the mold fee once. We store it. When you need more, you just pay for the patches.

How fast can I get patches in San Diego?

Molds take time. Expect 10–14 days for production. If you have a hard deadline, tell us upfront.