DSF

Paul, at 7 pounds each for the patch is not a bad price. Especially as its for a small quantity.
Digitising costs alone are around 20 plus pounds. The running costs of my Embroidery machines are around 25 pounds per hour, per head. A patch will take about 15 mins to sew out, and then cutting out, putting the glue on etc etc.

Im having a patch digitised in the US at the mo. Cost is $85. And then 15€ per patch to make them. 7 pounds is an OK price.

Daft question. Why dont you give the job to an embroidery shop and directly embroider them? Probably cheaper in the long run.

can you get blank patches?
if so i might be able to do them although i'd have to test it 1st obviously
to check the patch will stay in place etc

paul, vinyl press a good thick vinyl or even puff onto the patches, or just press vinyl directly onto the baseball caps