How to Cut and Heat Press Embroidered-Look TPU Patches | Part 2

Creating a custom patch that looks like traditional embroidery doesn't have to involve thread, needles, or an embroidery machine. With UV printing technology and TPU film, print shops can create detailed, textured patches that mimic the appearance of embroidery while maintaining the flexibility of a heat-applied decoration.

In Part 1 of our TPU Patch Series, we demonstrated how to use Adobe Illustrator, Mimaki RasterLink 7, and the Mimaki UJ330H-160 Hybrid UV Printer to create raised, embroidery-inspired textures on TPU film.

Now it's time to turn those printed designs into finished products.

In Part 2, we're walking through the process of cutting our UV-printed TPU patches and heat pressing them onto hats using a Mimaki CG-75 FXII Plus cutter and a Stahls' Hotronix 360 IQ Hat Press.

Watch: How to Cut and Heat Press TPU Patches

Watch Part 2 of our TPU Patch Series on YouTube

Step 1: Cutting UV-Printed TPU Patches

Once the textured UV printing is complete, the next step is cutting the individual patches out of the TPU film.

For this process, we're using the Mimaki CG-75 FXII Plus vinyl cutter to cut around our printed designs.

Accurate cutting is an important part of producing professional-looking patches. A clean, consistent edge helps create a finished product that looks intentional and maintains the shape of the original design.

Using a contour-cutting workflow, we can follow the shape of our artwork rather than being limited to basic squares or circles. This gives decorators more flexibility when producing custom logos, emblems, and specialty designs.

For the best results, it's important to properly align the printed artwork, use the correct cut settings for the TPU material, and inspect the finished edges before application.

Step 2: Heat Pressing TPU Patches onto Hats

With our patches cut and ready to go, it's time to apply them to our hats.

For this demonstration, we're using the Stahls' Hotronix 360 IQ Hat Press.

The Hotronix 360 IQ is particularly well suited for patch applications because it features independently controlled upper and lower heated platens. Its molded lower platen supports the curved shape of a hat, helping provide a more consistent application surface.

Proper positioning, temperature, pressure, and dwell time all play an important role in successfully applying a TPU patch.

Before pressing, make sure the patch is correctly positioned on the hat and that the application settings are appropriate for the specific TPU film, adhesive system, and hat material being used.

Once applied, the result is a dimensional patch that combines the raised appearance of embroidery with the detail and versatility of digital printing.

Why UV-Printed TPU Patches Are Worth Exploring

One of the most exciting aspects of UV printing is the ability to create products that go beyond traditional flat graphics.

By combining UV printing with TPU film, print shops can produce custom patches with raised borders, textured lettering, and embroidery-inspired patterns.

This opens up opportunities for products such as:

• Custom branded hats and headwear

• Corporate apparel and uniforms

• Sports team merchandise

• Promotional products

• Custom logos and specialty patches

For shops that already have UV printing equipment, developing a TPU patch workflow can be another way to expand their product offerings and create higher-value decorations for existing customers.

And because the designs are produced digitally, shops can experiment with different textures, colors, shapes, and finishes without needing traditional embroidery equipment.

Equipment and Materials Used

Here's the equipment we used throughout our TPU patch creation process:

• UV Printer: Mimaki UJ330H-160 Hybrid UV Printer — Used to print the detailed graphics and build the raised UV ink texture.

• Vinyl Cutter: Mimaki CG-75 FXII Plus — Used to contour cut the printed TPU patches.

• Hat Press: Stahls' Hotronix 360 IQ Hat Press — Used to heat apply the finished patches to hats.

• Material: TPU Film (Thermoplastic Polyurethane) — The flexible printing material used to create our dimensional patches.

Expand Your Printing Capabilities with Blue Ridge Screen Products

Whether you're an established screen printer, digital print shop, or apparel decorator, UV-printed TPU patches offer an exciting way to explore new products and printing techniques.

At Blue Ridge Screen Products, we're always experimenting with equipment, materials, and applications to help our customers get more out of their printing capabilities.

Interested in creating your own custom TPU patches? Explore our Mimaki UV printing equipment, shop our TPU film, or contact our team to learn more about the equipment used in this series.

Missed Part 1? Learn how to create textured, embroidered-look UV patches using TPU film.

Be sure to subscribe to our YouTube channel for more BRSP University tutorials, equipment demonstrations, and printing techniques.