How to Make 3D TPU Jersey Logo Patches with UV Printer
Author : KingJet
2025-12-12
In sports jerseys, team uniforms, or trendy apparel, logo patches are not only decorative but also symbols of identity, quality, and brand power. However, traditional processes often have shortcomings: embroidered logos can be heavy and not breathable, limiting design complexity and making small-batch production costly. Ordinary heat transfer DTF logos often lack three-dimensionality, are prone to cracking or peeling, and have a stiff feel. Traditional silicone logos require mold making, have high minimum order quantities, and cannot achieve gradient colors. So, are there better solutions? The answer is 3D TPU logo patches made using innovative UV printers.
This article will guide you through understanding what 3D TPU logo patches are, how to efficiently produce them, and why they are the best choice for apparel badge printing.
Table of Contents
What is 3D TPU Patch?
A 3D TPU patch is a multi-layered digitally printed badge made of thermoplastic polyurethane (TPU) film—a material known for its elasticity, abrasion resistance, and strong adhesion. Unlike ordinary flat heat transfer printing, the “3D” effect has a three-dimensional, embossed texture, bringing a high-end visual effect to jerseys and apparel.
Unlike flat printing and embroidery, 3D TPU logo patches are achieved by building up the height of white ink during the printing process. TPU-specific UV printers precisely stack the ink over a specified pattern area based on the white ink printing multiplier (4x, 6x, 10x selectable), creating an embossed structure.
These TPU logo designs are then transferred onto jerseys or other apparel using a heat press machine. Its high flexibility, combined with visual appeal and superior durability, makes it ideal for sportswear.
Why are 3D TPU Logo Patches Popular in Sportswear?
The rise of 3D TPU patches in sportswear is no accident. It’s a direct response from athletes, teams, and brands to the high demand for higher performance and customized apparel.
Unparalleled Durability
Sportswear needs to withstand sweat, friction, countless washes, and intense physical contact. 3D TPU patches are flexible enough to withstand prolonged activity without cracking, peeling, or abrasion.
Lightweight and Comfortable
Compared to heavy embroidery, these patches are very thin at their base, with weight added only to the raised design elements. This minimizes the feeling of restriction and improves the garment’s overall breathability and comfort.
Visual Appeal and Team Image
The glossy, three-dimensional effect conveys a sense of quality and artistic beauty. It can print vibrant full-color graphics, realistic details, and 3D effects, seamlessly integrating with various textile fabrics to enhance the overall design of team apparel, becoming an innovative element that combines fashion and function.
Personalization and Customization
3D TPU printers offer advantages in small-batch, highly flexible production, enabling “design-on-demand” mode. Users can adjust the shape, size, and 3D thickness of the jersey logo to meet their desire for uniqueness.
Step-by-Step Guide: How to Make 3D TPU Jersey Logo Patches with UV Printer
Step 1: Design the Jersey Logo Pattern
Use professional software to design a 3D logo pattern, choosing colors that contrast with the jersey fabric.
Step 2: Print with UV Printer
Use the 1060 UV flatbed printer or the 604LUV DTF printer to lay multiple layers of white TPU ink (4x, 6x, or 10x options available) on the TPU film, physically building a raised base for your logo. Next, colored inks and varnish are used for coloring and curing, ultimately creating a 3D embossed jersey logo with strong adhesion and high gloss.
Step 3: Cut the TPU Patch Logo
Use a cutting machine to precisely trim the edges. It can automatically follow the design outline and cut each patch with perfect precision, saving more time and effort.
Step 4: Heat Press Transfer
After printing, a heat press treatment is required. Position the patch on the jersey using the following parameters: temperature 150-160°C, time 10 seconds. Strict adherence to these parameters enhances adhesion between the patch and base material while ensuring compliance with performance metrics such as shrinkage and softness.
Step 5: Inspect the Final Product
Check adhesion and edge seal, test tensile and wash durability, and ensure even embossing and gloss effects.
Advantages of 3D TPU Jersey Logo Patches
The advantages of 3D TPU jersey logo patches go beyond just visual appeal. They represent a new generation of apparel decoration technology, combining durability, flexibility, and a high-end brand feel.
Stronger Visual Impact
- Unlike flat printing or ordinary heat transfer printing, 3D TPU patches have a raised, embossed texture that is highly attractive.
- The glossy effect and multiple colors add depth and sophistication, making them ideal for sports jerseys, fashion apparel, and promotional products.
Durability and Longevity
- TPU has extremely high abrasion resistance, resisting sweat and repeated wear, and stretching.
- It can withstand 50+ hand washes, and the markings still maintain good color after washing.
- UV-cured ink is firmly bonded to the TPU film, maintaining its integrity even during high-intensity exercise.
Comfort and Flexibility
- TPU patches are lightweight and flexible, conforming to the movement of the fabric.
- The smooth surface of TPU patches prevents skin friction and irritation.
Personalized Customization
- Supports multi-color, complex patterns, and fine detail printing.
- Logo patches can be matte, glossy, or textured.
Market Competitiveness
- TPU patches can be produced in small batches with rapid turnaround.
- TPU logo patches offer a premium, tactile feel that helps brands stand out.
Differences Between 3D TPU Patch Logo and Traditional Silicone Logo
Traditional liquid silicone logos are widely used in sportswear and fashion, but they have significant limitations compared to 3D TPU patches:
Production Complexity
TPU patches can be produced directly via UV printers without mold creation. Silicone logos require mold development, entailing high upfront costs and extended lead times, making them unsuitable for small-batch or customized production.
Minimum Order Quantity
TPU patches support small-batch production, ideal for startups or limited editions. Silicone logos typically demand higher minimum orders due to mold costs.
Cost and Efficiency
Silicone logos involve substantial upfront investment and limited design flexibility, making intricate details or gradient colors difficult to achieve. TPU decals allow free design adjustments and color printing, offering greater creative freedom. Their simpler printing process also results in higher production efficiency.
Differences Between 3D TPU Patch Logo and Embroidered Logo
Embroidery has long been the traditional method for applying logos to jerseys and apparel. While it offers a handcrafted feel, it differs significantly from 3D TPU patches:
Comfort
Embroidered patches may feel rough against the skin, especially on athletic jerseys; TPU patches are smooth and flexible, ensuring a comfortable experience.
Modern Aesthetic
Embroidery conveys a traditional craftsmanship feel, while TPU patches present a clean, contemporary look that aligns better with today’s fashion and sports markets.
Cost Efficiency
Embroidery involves complex processes and high labor costs, making it expensive for small-batch production; TPU patches can be produced quickly and cost-effectively, remaining economical even for small quantities.
Differences Between 3D TPU Patch Logo and DTF Transfer Logo
DTF (Direct Transfer Printing) has become popular in recent years due to its ability to achieve full-color transfer. However, compared with 3D TPU patches, there are four key differences:
Visual Effect
DTF apparel logos are flat. While they reproduce colors well, they lack the raised, three-dimensional effect, glossy texture, and tactile depth that make jersey logo patches stand out.
Durability
In sports settings, DTF patterns are prone to cracking, peeling, or fading after repeated washing. TPU logo patches, combining UV-cured ink and hot-pressing technology, can remain intact even after 50+ washes.
Production Efficiency
DTF printing requires powder and curing, increasing the workflow. 3D TPU patches are printed directly by a UV printer, resulting in faster production and higher efficiency.
Customization
DTF can achieve gradient and full-color designs, but it cannot achieve glossy or embossed effects. TPU patches support a variety of effects, such as matte and glossy, and can accurately reproduce complex details.
Comparison Between 3D TPU Logo Patches and Other Logos Processes
The following is a detailed comparison between 3D TPU logo patches and traditional liquid silicone logos, embroidered logos, and DTF (Direct-to-Film) transfer logos.
| Logo Type | 3D TPU logo patch | liquid silicone logo | DTF transfer logo | Embroidered logo |
| 3D / Texture | Yes | Yes | No | No |
| Feel | Flexible | Rubbery feel | film layer | Stiff |
| Color and Detail | Vibrant and realistic colors | Limited colors | Full color | Limited colors, no gradients |
| Durability | Excellent, abrasion-resistant | Excellent | Average | Good |
| Cost | Medium | High, high mold cost | Medium | Medium |
| Minimum Order Quantity | Low | High | Low | Medium |
| Production Speed | Fast (direct printing) | Slow (forming, curing) | Slow (shaking powder, curing) | Slow (Wire Change) |
| Business Model | Customization, small batches, great detail | mass production | low cost, short-term use | traditional, business appearance |
Beyond Jerseys: Diverse Applications of 3D TPU Logo Patches
While jersey logo patches are the most common application, the uses of 3D TPU patches extend far beyond the sports field:
Sports and Outdoor Gear: Backpacks, cycling apparel, fitness wear, hats, tents.
Branded Workwear and Safety Clothing: Corporate uniforms, safety vests, functional clothing.
Fashion Items: Streetwear, brand logos on denim jackets, limited-edition apparel.
Footwear Brands: Athletic and trendy shoes increasingly use TPU patches as logos.
Conclusion
Using UV printers to create 3D TPU jersey logo patches represents a smart upgrade for athletic apparel and fashion brands. TPU patches deliver unmatched durability, flexibility, and premium dimensionality—qualities that embroidery, silicone, or DTF simply cannot rival.
For teams, it means more durable, professional-grade jerseys; for brands, it unlocks creative possibilities like gradients, glossy finishes, and intricate designs; for small businesses, it offers a cost-effective path to customization.
To learn more about 3D TPU jersey logo patches, consult the professional KingJet team with 18 years of experience in the printer industry. We will provide you with exclusive services. Contact Us Now
FAQ
How many washes can the 3D TPU patch withstand?
Under normal washing conditions, it can withstand 50+ washes. After washing, the logo still maintains good color, three-dimensionality, and adhesion, with no obvious fading or peeling, meeting the durability requirements for daily use.
Can any UV printer print TPU patches?
No, only UV printers compatible with TPU inks and flexible TPU films can print them, such as the KingJet 1060 UV flatbed printer or the 604LUV DTF TPU patch printer.
Can TPU logo patches be applied to any fabric?
3D TPU patches can be applied to almost all fabrics, but they work best with synthetic fiber fabrics such as polyester and nylon, and are commonly found in sportswear.
