How to Design and Create Your Patch With Aviator Gear

Looking to design your own squadron or unit patch? You’ve come to the right place! We’ve outlined the steps below to help you design your very own custom patch. Don't worry if you are not the creative type, because we provide free artwork and design services. If you want to see some of the designs we’ve created in the past, head on over to our Patch Design Gallery or check out the Squadron Patches we've made for our customers.

Our patches are 100% embroidered without any setup charges. We will create custom artwork free of charge for orders of 100 patches or more. For quantities lower than 100, our artwork charge is just $50.00 with unlimited revisions. Our designers will work with you, making changes and tweaking the design until you are thrilled with the result and we are confident it will create a great patch. Here are some Frequently Asked Questions. We’ve outlined the steps below to help you design your very own custom patch.

Contact Us

Start the process of creating your own custom patch by submitting your inquiry through email at or by using the Request a Patch Quote link on our website. Try to include as many of the following details as possible:

  • The height of the patch in inches. Common sizes are 3” tall, 3.5” tall, and 4” tall.
  • A rough idea of the quantity that you plan to order.
  • We do not need much to get started. Whether you are proficient with Photoshop, a brilliant artist, or just using stick figures on a pizza box; send us what you have so far and we will bring your ideas to life!

We will get back to you with a price quote within 24 hours, and start the process to design your patch.

Artwork and Revisions

After you approve the quote, we will get started creating the custom artwork for your patch. We should be able to provide a first draft of the artwork in 4-5 days for you to review and provide feedback and revisions.

Whether designing a squadron, Friday, morale, or pencil patch; there are a few things to consider that will ensure you receive a great looking, high quality patch that your squadron will be proud to wear.

  • KISS: “Keep It Simple Soldier”. We understand that you want to put a little bit of everything that makes your squadron iconic on your patch. A wonderful idea--in theory, but not very practical or realistic if you want to create a quality patch.
  • Colors: We do not need a color copy, but it’s helpful for us to know the colors you envision. We are experts on The Institute of Heraldry’s (TIOH) standards for military emblems and we will apply these standards to your design. Here is an overview of the Rules of Military Heraldry.
  • Patch Size: The size of the fuzzy Velcro on most flight suits is 4" x 4". A larger patch will hang off the Velcro and tends to get caught on just about every piece of fabric that you walk by. We highly recommend a maximum size of 4” tall or wide for flight suit patches.
  • Text Size: To get the best results, the text should be at least 1/4th of an inch tall. With smaller text it is difficult to manipulate the stitches into letters or numbers, such as “8” or “R”.
  • Type of Border: There are a couple different border options; merrow, heat cut, and leather. The merrow or overlock border is common for military squadron patches. The USAF major command (MAJCOM) and Wing patches use a heat cut border. A heat cut border is also better for designs with an odd shape. Leather borders can be added to any patch and you can also add a merrow border to the edge of a leather border. Here are some examples of patch border options.
  • Faces: Pinup girls and celebrities are great ideas; but the fact is, facial features are extremely challenging to replicate with thread. Unless the person’s face is animated, like a cartoon, or takes up at least 2/3 the space on your just won't work.

Resource Links

Placing Your Order

After the artwork is final, we will prepare your invoice and provide payment instructions.

Creating the Sample Patch

After we receive your payment, we will create a sample of your patch, which will take 4-5 business days. We will email a digital photo of the sample patch for your review. We will still be able to make final adjustments and revisions at this time.

Patch Production

Once you approve the sample patch, we will enter your order into full production. Production will take us about 4 weeks.


Once we have completed production, we will pack and ship to you via USPS Priority Mail with 2-3 days transit time. UPS Ground service is also available, just let us know if that works better for you. We will email your tracking number, so you can monitor the shipment all the way to your doorstep.

Start Designing Your Own Custom Patches

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221 N Hogan St, Ste 369
Jacksonville, FL 32202

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