Good TPU patch results start at design stage. The steel die is a one-time investment that lives across the entire product life — careful design pays off.
📌 File Format
Vector files (AI, CDR, EPS, vector PDF) are mandatory for the die outline. The emboss depth profile is communicated as a separate layer or specification document.
📌 Emboss Depth
Standard emboss is 0.3–0.6 mm. Deeper emboss (up to 1.5 mm) is possible but requires thicker base TPU. Sharp internal corners (under 60°) cannot be embossed cleanly.
📌 Minimum Text Height
Minimum legible cap height in HF emboss is 1.5 mm. Smaller text loses definition. For finer text, use printed (non-embossed) regions of the patch.
📌 Colour Separation
TPU patches support up to 4 colours via HF print before emboss. Each colour requires a separate process step and registration. Plan colours sparingly.
📌 Pantone Matching
Pantone solid coated colours are matched precisely. CMYK halftones are not used for HF printing — solid spot colours only. For brand colour fidelity, supply Pantone references in the brief.
📌 Die Cost
The steel die is a one-off investment, typically amortised across the first 1000 pieces. Re-orders against the same design re-use the die at no further setup cost.
📌 Sample Process
For new designs we strongly recommend a paid sample run after the die is made — verify colour, emboss and dimensional accuracy before full production.