Ever got curious about how PVC patches are made? that you see almost everywhere around you, on uniforms, on garments to design them, on hats to personalise them, on backpacks to upgrade the look.
These multi-purpose patches require utmost care, industrial machinery, and processes in their making process, which is why it is highly unlikely to make PVC patches at home.
What are PVC Patches?
What is a PVC patch? PVC patches are actually flexible rubber patches. They are not made from fabric or embroidery. People often use PVC patches for logos and name tags since they are more durable than embroidery or any other patches.
PVC patches don’t absorb water, and they are heat-resistant. The colors don’t fade easily, and they are suitable for outdoor use. They don’t fray like fabric patches and are easy to clean, which is why they are preferred over other patch types.
What PVC Patches Are Made Of?
PVC patches are made of soft polyvinyl chloride. The PVC powder, called PVC resin, is mixed with additives, plasticizers, stabilizers, and pigments to give it color and aid molding and hardening, balancing softness and flexibility.
Let’s brief out PVC patch manufacturing process.
Process of Making PVC Patches
Making PVC patches at home can be pretty tricky because they require molds for each design. It’s better to get them ready from a PVC patch manufacturer. If you are still looking for how PVC patches are made, it is precisely outlined below, step by step.
Design
Designing your patch is the first most important step in the PVC patch manufacturing process. You have to design your patch according to how you want your patch to look visually. You can simply draw a sketch of your design and then digitalize it using Adobe Photoshop or CorelDRAW.
Once done, you can send your design to the patch maker and they revise your design in vector format in color layers, each layer is set to a specific height to give them a 3D look.
Mold
The second most important thing in the PVC patch manufacturing process is the mold, the industries use a CNC engraving machine to engrave the design onto the steel or aluminum, each design needs a different mold.
Preparing PVC Material
The next step that comes after the mold is ready, that is to prepare the soft polyvinyl chloride for molding, the base material that’s taken is polyvinyl chloride and is mixed with additives such as pigments, to add colors to your patch, stabilizers to protect the PVC patches from burning and discoloration during the heating process and plasticizers to add softness and flexibility to your PVC patches.
Furthermore, the UV stabilizers for sun protection and anti-bacterial agents can be added while making sure the mixture is not too thin that the colors might spread or not too thick that the mixture won’t flow into the mold.
Dispensing PVC Liquid
The next step in the PVC patches making process is to pour the PVC mixture into the mold. This step needs most of the care and precision.
The soft polyvinyl chloride is poured into the mold using automated dispensing machines or manually through squeeze bottles or a syringe for small parts. The first layer of PVC is then poured in thin lines, text and edges where needed, then partial heat is provided to the mold at 100 to 120 degrees for 1 to 2 minutes to turn the PVC into a semi-solid gel-like form to avoid the layers from mixing.
Curing with Heat
After all the layers are filled, the PVC patches are heated in the mold at 160 to 200 degrees in an industrial oven or furnace for 5 to 10 minutes depending on the thickness until the PVC is cured and solidified.
Demolding
After heating the mold, the molds go through a cooling process, then the patches are peeled out through machines or manually.
Patch Finishing Process
After the patches are demolded the edges and any excess material that is called flash are trimmed off from the patches then the matte or shiny protection varnish is applied on to the patch.
Backing
In the final step, the backings are attached to the patches using heat press or glue bonding according to the desire of the client since there are different backing options, like iron on that can be attached to the fabric using heat, sew on method in which patch is being sewn directly onto the fabric, or velcro patches that are removable.
How to Use PVC Patches
PVC patches can be used on anything like:
- Jackets
- Jeans
- Bags
- Hats
- Uniforms
- Shoes
They can be used as:
- Name plates
- Unit insignia
- Morale patches
- Keychains
- Charms
- Designer label
How to Clean PVC Patches
For PVC patch care cleaning them is necessary:
- For mild dust you can clean the PVC patch with a clean, soaked cloth.
- For mud, grease or stubborn dust you can clean the patch with a mild soap mixed with water.
- For deep cleaning of detailed 3D patches you can use a soft brush with mild soap to scrub and clean between the lines.
FAQs
How long do PVC patches last?
Even under harsh conditions, PVC patches may last for years, with proper care.
Is PVC 100% water proof?
Yes, naturally, PVC is 100% water proof.
Is PVC basically plastic?
Yes, PVC is a soft plastic that is almost like rubber.
What is the main ingredient for PVC?
The main ingredient for PVC is polymerized molecules of vinyl chloride monomer.
Can PVC patches be made at home?
It is highly unlikely to make PVC patches at home because they require industrial heating processes and ventilation that can not be performed at home.
Why Not Have a Ready Made PVC Patch
PVC patches are a great way to personalize your apparel, showcase your art and identity and are more durable than any other patches, they are good for outside use since they are waterproof , and can bear weather conditions flawlessly without fading.
A good quality patch can last longer than a year, you can get the best quality bespoke pvc patches from The American Patch, whether you want to upgrade your clothes, personalise your apparel or items, or build an identity.
