What Is the Process of Producing 3D Silicone or PVC Patches?
3D silicone or PVC patches have become a popular choice for brands, uniforms, outdoor gear, and fashion accessories due to their durability, weather resistance, and high-end look. Unlike embroidered or woven patches, silicone patches offer a bold, three-dimensional finish that feels modern and tactile.
But what exactly goes into creating a custom 3D silicone or PVC patch? Here’s a step-by-step breakdown of the production process.
1. Design Development
Everything starts with a design. You provide your logo, artwork, or idea, and the manufacturer converts it into a digital format suitable for 3D molding.
Vector artwork (like CDR, AI, EPS, or SVG) is required for accuracy.
If 3D effects or layers are needed, the design is broken down into sections by height and colour.
Pantone colour matching is often used to ensure consistency.
Tip: Simpler designs with bold elements usually translate best to 3D silicone.
2. Mold Making
Once the design is finalised, a custom metal mold is created.
This mold is CNC-machined based on the digital 3D layout.
The mold has recessed areas (for raised details) and raised areas (for sunken effects).
Tooling/mold setup is a one-time cost and typically takes 5–10 days to produce.
Note: Mold fees can range from $250+ depending on patch type, size and complexity.
3. Colour Mixing & Silicone Preparation
Silicone / PVC rubber is mixed and coloured according to the design specifications.
Colour pigments are blended in, using Pantone codes for accuracy.
Multiple colour layers may be prepared if the design includes several raised areas.
4. Molding & Curing
With the mold ready and silicone / PVC prepared, the patch is formed using a compression molding process.
Silicone / PVC is poured or injected into the mold.
The mold is heated and pressed under high pressure to shape the silicone.
Each colour and layer may be added and cured separately to build up the 3D relief.
This step gives the patch its distinctive raised texture and clean edges.
5. Finishing Touches
After the molding process, patches are trimmed, cleaned, and inspected.
Any excess silicone (called “flash”) is removed manually.
Optional finishes like matte, gloss, or textured surfaces can be applied.
Backing options (like Velcro, adhesive, sew-on, or heat-press) are added at this stage.
6. Quality Control & Packing
Each patch is checked for detail, colour, shape, and finish consistency before packing.
Quantity, packaging type (bulk, individual, etc.), and delivery method are finalised.
The finished product is now ready to be shipped to the customer.
Why Choose 3D Silicone Patches?
Weatherproof & UV resistant
Long-lasting and flexible
Vibrant, high-impact branding
Customisable in shape, size, and colour
Final Thoughts
Although producing 3D silicone patches involves multiple technical steps and a tooling setup, the final result is a durable, eye-catching patch that stands out from traditional embroidery or printing. Whether you need them for promotional items, fashion branding, or tactical gear—silicone patches offer both function and flair.
Need Custom 3D Silicone Patches?
We can help you bring your design to life. Contact us today for a quote or free artwork check!