Plastic is a light, flexible, and durable material. As a result, PVC patches are significantly lighter than patches made from embroidery. This makes it easier to attach PVC patches to even very thin pieces of clothing and uniforms without fear of weighing down the fabric or making it less comfortable to wear. With PVC, it’s easy to forget that the patches are even there when not looking at them.
Embroidery machines can’t render any detail smaller than the length of one of its stitches. This forces the design of embroidered patches to be bold and simple, as any intricate details or shading won’t come across on the final product. PVC, on the other hand, is poured into molds and painted after, which leaves room for much more detail in shade and color. And as the PVC patches vs embroidered patches guide found on this website explains, PVC patches can even be given added texture through the use of 3D molds.