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When “Close Enough” Wasn’t Good Enough for the Original Artwork
Who: A Customer Looking for Better Design Fidelity
The customer came to AWELLS with a detailed shield-shaped patch design featuring a working dog portrait, curved lettering and several small graphic elements.
The artwork had already been discussed with other suppliers, but the customer was not satisfied with the results. Too many details had been simplified during production, changing the overall look of the original design.
For this project, the customer's main concern was clear:
the finished PVC patch needed to stay as close as possible to the approved artwork.
What: 2D Soft PVC Combined with UV Printing
After reviewing the artwork, AWELLS did not rely on PVC molding alone.
Instead, we proposed a combination of:
2D Soft PVC + High-Resolution UV Printing
The PVC structure was used to create the shield shape, borders and raised graphic areas, while UV printing helped retain finer image details that would be difficult to reproduce through molded PVC alone.
The confirmed specification included:
Size: 80 × 100 mm
Thickness: 2.5 mm
Shape: Shield
Material: Soft PVC
Process: 2D PVC + UV Print
Backing: Molded Hook & Loop Backing
This mixed-process solution allowed us to keep the dimensional appearance of a custom PVC patch while reproducing more of the customer's original artwork.
Why: Why the Customer Continued with AWELLS
The customer was not simply looking for another supplier who could manufacture a rubber patch.
The real requirement was finding a production solution that respected the original design.
AWELLS supported the project in four key areas:
Artwork Review
We evaluated which details could be produced in PVC and which were better retained through printing.
Combined Production Process
2D soft PVC and UV printing were used together rather than forcing every detail into one process.
Detail Preservation
The portrait, lettering and overall shield composition remained visually close to the supplied artwork.
Sample Confirmation
The customer reviewed the sample before the project moved forward.
This flexibility is especially valuable for buyers sourcing custom PVC patches, custom badges and custom emblems with detailed logos, portraits or complex artwork.
Result: Sample Approved — Then Another Order Followed
After receiving the sample, the customer's response was simple:
“Sample looks good!”
The customer also gave positive feedback on the product quality, service and delivery.
More importantly, the conversation did not end with the first order.
Soon afterward, the customer contacted AWELLS again:
“Cindy, new order. Can you give me the payment method for the other patch please?”
That follow-up is one of the clearest outcomes of the project.
Instead of only approving the original sample, the customer moved on to another patch order, turning a single custom project into continued cooperation.
From Detailed Artwork to Production-Ready PVC Patches
Complex artwork does not always need to be simplified just to fit a standard production method.
By combining different processes according to the design, AWELLS can support custom PVC patches, badges and emblems with more flexible solutions for logos, lettering, detailed graphics and special shapes.
Customization is available for size, shape, PVC structure, color, printed details, backing and packaging, based on confirmed project requirements.
