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Turning a Custom Design Into a Production-Ready IR Patch
Who: A Customer Needed a More Flexible IR Patch Solution
A customer approached AWELLS with a complex design for a custom IR patch.
The required patch measured approximately 127 mm and included multiple pattern and color variations. The main challenge was that there was no ready-made camouflage fabric base that closely matched the customer's artwork.
Using an unsuitable stock fabric would have limited the final design and reduced visual consistency.
What: Custom Printing + Reflective Patch Construction
Instead of relying on an existing patterned fabric, AWELLS used a blank Oxford fabric base and applied the customer's design according to the confirmed artwork.
The finished patch construction included:
Black Oxford Fabric + Reflective Film + Laser-Cut Edge + Hook & Loop Backing
This solution allowed greater flexibility for different patterns while maintaining the structure required for the customer's custom patch badges.
Bulk packaging was selected for the finished order.
Why: Why the Customer Chose AWELLS
The project required more than choosing an existing material. AWELLS adjusted the production method around the customer's artwork.
Our support included:
- Custom Artwork Adaptation — the pattern was produced according to the customer's design rather than limited by stock fabric.
- Material Combination — Oxford fabric and reflective film were combined for the required patch construction.
- Laser-Cut Finishing — clean edges helped maintain the rectangular shape and overall appearance.
- Sample & Production Confirmation — the customer reviewed the solution before approving production.
For buyers sourcing custom patches, badges and emblems, this type of flexible production support can be especially useful when standard materials cannot reproduce the intended artwork.
Result: Approved for Production and Repeat-Order Interest
After reviewing the solution, the customer confirmed:
“Yes this looks fine. Please start making these.”
The customer also asked how quickly AWELLS could produce another order of the same product, showing clear interest in future repeat production.
The project demonstrates how AWELLS can adapt materials and processes when a standard patch solution does not fully match a customer's design requirements.
Custom Patches for Your Next Project
AWELLS supports customized patches, badges and emblems for apparel, bags, outdoor equipment and identification applications.
Custom options can include artwork, size, pattern, material, edge finishing, backing and packaging, based on confirmed order requirements.