Sew-On Badge Patches in Ireland: What Should I Look For Before I Order?

[jamesaderson]

Hi everyone,

I’m organising badges for a youth group here in Ireland, about 40 members, and I’d like sew-on badge patches that will last more than a season. We’ve used iron-on ones before and they started peeling after a few washes, so this time I want something that will hold up properly.

I’ve looked at a few suppliers, but the options and prices are all over the place, and I’m not sure what’s worth paying extra for. Since I’m no expert, I’d appreciate advice from anyone who has been through this:

Are sew-on patches really that much more durable than iron-on, and is it worth the extra effort of sewing?
What size works best for badges on shirts and jackets, so the detail stays readable?
Is a merrowed (stitched) border worth it over a plain cut edge?
How many colours can a design have before the price jumps?
What file format should I send for the artwork, and do I need a vector file?
What are typical minimum order quantities and delivery times within Ireland?
Do suppliers usually send a proof before production?

I’d also like to hear about mistakes to avoid, like ordering the wrong size or colours that look different once they’re stitched. Any photos of badges you’ve had made would help me work out what’s realistic.

Thanks in advance, all advice is welcome!