The first step in producing a soft PVC patch is a well-prepared design file. The clearer the file, the more smoothly mould preparation, colour work and approval go. We wrote this guide especially for brand designers, advertising agencies and collection teams. Step by step, we explain what a soft PVC patch file should contain.
1. Use a vector file
The most suitable format for patch artwork is a vector file such as AI, EPS, PDF or SVG. In a vector drawing, lines and edges stay sharp whether the size grows or shrinks, which matters for defining contours and colour areas correctly in mould preparation. If you only have an image such as a JPG or PNG, send it anyway; we will review the design together and, if needed, discuss converting it to vector.
2. Convert text to outlines
The fonts used in your file may not be available on our side. Converting text to outlines makes the letters appear exactly as you designed them. In the same way, the final form of fine details and letter spacing should be fixed in the file.
3. State the real size
Giving the patch’s real size on the product (width and height) in millimetres makes it easier to judge whether the design is workable. As size decreases, thin lines and small text become harder. If your logo has a very thin sub-line, we check together whether it stays legible at real size, and suggest changes to letter weight or layout if needed.
4. Define colours with codes
On a soft PVC patch, each colour is filled into its own area of the mould, so every colour in the design needs a clear code. Pantone codes are a common reference. Along with the codes, it helps to state how many colours the design has. Gradients, shadows and very fine tonal transitions work differently in a moulded method; if your design has such effects, we can plan a simplified version together.
5. Show the raised layers
Relief is what gives a soft PVC patch its character. It is important to indicate which parts rise above the base and which stay at base level. For example, the logo may be raised and the background flat, or layers of different heights can be planned within the logo. Adding this as a separate layer or a simple note is enough.
6. Define the contour and cut shape
A patch can be rectangular, round or oval, or produced with a contour cut that follows the logo’s outline. Showing the cut shape as a separate line in the file removes uncertainty in mould preparation. For patches that will be sewn on, a stitching margin at the edge should also be considered.
7. Add application details
Which product and which area will carry the patch affects design decisions. A cap front panel, a jacket sleeve or a bag flap each bring different size and flexibility needs. Stating the product type and colour lets us give more accurate advice on colour contrast and size.
Short checklist
- Vector file (AI, EPS, PDF or SVG)
- Text converted to outlines
- Real size (mm)
- Colour codes and number of colours
- Raised layers
- Cut shape and stitching margin
- Target product and its colour
The approval process
Once we receive the file, we review the design and share our notes on feasibility. If needed we suggest small adjustments and present the final version for your approval. Mould preparation starts only after that approval, so there is a clear shared understanding from the start of how the patch will look.
Common mistakes
The issues we see most often in design files are: text not converted to outlines, no size given, colours defined only by screen values, and separate colours assigned to very thin lines. In images without a transparent background, the real edge of the patch can also be unclear. Watching these points from the start reduces revision rounds and helps the project move faster.
Frequently asked questions
What if I don’t have a vector file?
Send your existing image (JPG or PNG). We will review the design and discuss with you the need for vector conversion and any possible adjustments.
Can a logo with gradients be made into a patch?
On a soft PVC patch, colours are filled into separate areas of the mould, so soft tonal transitions work differently. Planning a simplified version with clean colour areas instead of gradients usually gives a better result.
When does mould preparation start?
After the final design has been approved by you. Before approval, we share our feasibility notes and suggestions.
Conclusion
A well-prepared design file is the most important step towards a soft PVC patch that looks the way you expect. For sample models, see our soft PVC patches page and send your file through our quote form. We can also work the same design as a rubber label.