Custom Cut Applique Quote Form

Fill out the form below to place an order, or send an email to sales@twillusa.com with your contact information attached or call (866) 806-9120 for immediate assistance. You may also order or inquire by fax — (812) 926-0634. Please include any logos and/or designs, graphics, and images in .ai, .eps, .jpeg, .png or .pdf formats.

One Color Layout Example for Custom Cut Applique

One Color

Two Color Layout Example for Custom Cut Applique

Two Colors

Three Color Layout Example for Custom Cut Applique

Three Colors

Straight Layout Example for Custom Cut Applique

Straight

Tilt with Slant Layout Example for Custom Cut Applique

Tilt + Slant

Bridge Layout Example for Custom Cut Applique

Bridge

Half Arch Shadow Layout Example for Custom Cut Applique

Half Arch Shadow

Vertical Arch Layout Example for Custom Cut Applique

Vertical Arch

Double Arch Layout Example for Custom Cut Applique

Double Arch

Tilt Layout Example for Custom Cut Applique

Tilt

Double Inset Reverse Arch Layout Example for Custom Cut Applique

Double Reverse Arch

Inset with Bookends Layout Example for Custom Cut Applique

Inset + Bookends

Inset Arch with Bookends Layout Example for Custom Cut Applique

Inset Arch + Bookends

True Arch Layout Example for Custom Cut Applique

True Arch

Reverse Bridge Layout Example for Custom Cut Applique

Reverse Bridge

Athletic Script with Tail Layout Example for Custom Cut Applique

Athletic Script + Tail

Brush Script with Tail Layout Example for Custom Cut Applique

Brush Script + #5 Tail

Zipper Split Layout Example for Custom Cut Applique

Zipper Split

Overlap Split Layout Example for Custom Cut Applique

1.5″ Overlap Split

Pre-Spaced Background Layout Example for Custom Cut Applique

Pre-Spaced Background

Connected Background Layout Example for Custom Cut Applique

Connected Background

Cloud Background Layout Example for Custom Cut Applique

Cloud Background

STEP ONE: CHOOSE SIZE & QUANTITY *
Select an option from the list of common sizes or choose HEIGHT from 2" up to 12" and WIDTH from 4" up to 18" from the dropdowns below. HINT: You may select multiple options from the list by holding the Control (Windows) or Command (Mac) key while making your selections. View Prices ›

Custom Size?

* QUANTITY
NOTE: Orders for less than 5 pieces will be charged a $10.00 'Under Minimum Fee'


STEP TWO: CHOOSE TYPEFACE *
We have hundreds of fonts to choose from, but the most popular fonts are Full Block (also known as 'Varsity'), Plain Block (also known as 'Pro'), Brush Script, Athletic Script and Greek. Additional fonts include USA, Stamp, Wedge, Cooper, Striped, Tiffany, Collegiate, Bold Block, Full Block Fade, Full Block Gap Outline and many more. Select OTHER from the dropdown if you know the name of the font you wish to use.

Click to view an image of Full Block and Plain Block Letters

Specific Font Type?

Click to view an image of our Additional Letter Fonts


STEP THREE: CHOOSE MATERIAL *
We offer Custom Cut Applique in the following fabrics and HTV materials: Sports Twill, Metallic Twill, Fashion Fabrics, Sports Felt, Sports Film, HTV Glitter, Flex Film and HTV Foil. Some materials offer several adhesive backing options, including Polyback, PSA, Permanent, PSA Permanent and Uncoated. NOTE: Some materials cannot be layered together and/or may not be used as a Background layer.

Are You Sewing (Applique)? NoYes


STEP FOUR: CHOOSE COLORS *
Custom Cut Applique can be layered with different colors and materials. Please select the Background, Middleground and Foreground colors, as well as additional colors in the extra fields below if you're Sublimating the design.

Additional Colors?

Click to view an image of our Color Charts


STEP FIVE: CHOOSE LAYOUT *

TiltStraightTrue ArchDouble ArchVertical ArchTilt with Slant
BridgeReverse BridgeHalf Arch ShadowInset with BookendsInset Arch with BookendsScript with Tail

Click to view an image of our Custom Cut Layout styles

CHOOSE TAIL (if applicable)

Click to view an image of our Custom Cut Tail and Split Front options

SPLIT FRONT? (Add $15.00)
Zipper Split (Flush)1.5'' Overlap Split

Space Between Buttons?


STEP SIX: CHOOSE BACKGROUND *
Pre-Spaced Backgrounds require the use of Green Tape, which carries a surcharge of 25%. Connected and Cloud Backgrounds do not require the use of Green Tape. TIP: Connected Backgrounds (including Cloud) are quicker and easier to apply to garments compared to the Pre-Spaced option.
Click to view an image of our Background styles

Pre-SpacedConnectedCloud

Add Green Tape? NoYes


STEP SEVEN: LOGO / ARTWORK UPLOAD
Upload an existing logo or digital image and our in-house graphics department will design your artwork onto a proof for your review. Please include any graphics or images in .ai, .eps, .jpeg, .png or .pdf formats.


STEP EIGHT: CHOOSE SEW FILE

One Color ($25.00)Two Color ($30.00)Three Color ($35.00)Split Front ($38.00)


STEP NINE: YOUR CONTACT INFO *

Name:
Email:
Phone:
Company:

PREFERRED CONTACT METHOD *
PhoneEmail


STEP TEN: ADDITIONAL LAYOUT INFO / REQUESTS

How To Place An Order

With production facilities in Indiana and Nevada, Twill USA makes Heat Transfer Vinyl (HTV) and Tackle Twill fabrics for the sports apparel industry. Your business is very important to us. Please email any questions or concerns to sales@twillusa.com with your information attached or call (866) 806-9120 for immediate assistance. Hours of operation are 8:00 AM–5:30 PM ET. Our USA-based Customer Service Team will help you to set up an account. A business application and resale certificate may be required for business accounts. All orders must be paid by credit card unless NET 30 Terms have been approved (see Payment Methods). We cannot be held responsible for errors on phone orders. To ensure accuracy, we recommend written purchase orders (POs) or written confirmation whenever possible.

Frequently Asked Questions

Q: What Is Custom Applique?

A: Applique is used as an alternative to embroidery. Applique allows for multicolor, multilayer designs with a minimal amount of stitching. It can save time money while enhancing the look of the garment. Custom applique is a way to embellish apparel like athletic jerseys and activewear with an exact style and appearance. As opposed to stock designs, fonts or clip art, custom applique is available in a wide variety of colors, fabrics and textures.

Q: How Much Does It Cost?

A: The price chart below shows the cost for 2-color assembled designs, which is the most popular option. There is a 5 piece minimum (re-orders are exempted from this policy). Orders for fewer than 5 pieces will be charged an ‘Under Minimum Fee’ of $10.00. There is a $10.00 charge for initial setup, which includes a proof to scale. Add 25% for pre-spaced logos with green tape.

CUSTOM CUT APPLIQUE PRICE GUIDE
QUANTITY 5–9 10–29 30–49 50–99 100-200+
Youth $5.61 $3.55 $3.31 $3.09 $2.90
Youth with Tail $7.53 $4.78 $4.44 $4.15 $3.89
Adult $6.83 $4.49 $4.17 $3.86 $3.66
Adult with Tail $8.75 $5.72 $5.30 $4.92 $4.65
Pro $8.13 $5.37 $4.90 $4.67 $4.46
Pro with Tail $10.82 $7.15 $6.51 $6.21 $5.95
Jacket $9.27 $6.13 $5.60 $5.32 $5.09
Jacket with Tail $11.96 $7.91 $7.21 $6.86 $6.58
Jumbo $10.09 $6.81 $6.24 $5.98 $5.73
Jumbo with Tail $14.06 $9.41 $8.60 $8.25 $7.91


ADD A WORD INSIDE OF TAIL
ALL SIZES $0.87 $0.51 $0.42 $0.39 $0.38


NO SEW PRICE GUIDE
QUANTITY 5–9 10–29 30–49 50–99 100-200+
Cap / Left Chest $3.75 $3.09 $2.59 $2.29 $2.09
Youth $7.01 $4.42 $4.14 $3.86 $3.63
Youth with Tail $9.41 $5.96 $5.55 $5.19 $4.87
Adult $8.54 $5.61 $5.21 $4.83 $4.58
Adult with Tail $10.94 $7.15 $6.62 $6.16 $5.82
Pro $10.16 $6.71 $6.13 $5.84 $5.58
Pro with Tail $13.52 $8.94 $8.14 $7.77 $7.44
Jacket $11.59 $7.66 $7.00 $6.65 $6.36
Jacket with Tail $14.95 $9.89 $9.01 $8.58 $8.22
Jumbo $12.61 $8.51 $7.80 $7.48 $7.16
Jumbo with Tail $15.97 $10.74 $9.81 $9.41 $9.02

* No Sew eliminates the time and cost of embroidering as the design is permanently heat applied onto garments.

Q: How Large Can You Make My Design?

A: Your design(s) can be up to 50” wide by 50” deep. Typical designs are 12” or less for jackets and shirts, as the material begins to wrap around the body if it is any larger. Please review the size chart below to better estimate the cost of your project when referencing the Custom Cut Applique Price Guide above.


SIZE CHART
Cap / Left Chest Height 3″ & Width Up To 4″ Up To 12 Square Inches
Youth Front Height 3″ & Width Up To 10″ Up To 30 Square Inches
Adult Front Height 3.5″ & Width Up To 14″ Up To 50 Square Inches
Pro Front Height 4.5″ & Width Up To 17″ Up To 80 Square Inches
Jacket Back Height 5″ & Width Up To 18″ Up To 90 Square Inches
Jumbo Height 7″ & Width Up To 18″ Up To 130 Square Inches

Q: Can You Embroider My Logo For Me?

A: We do not offer embroidery services as the applique is designed to replace and enhance the embroidered look. We do offer sew files with our custom cut appliques so that the edges can be sewn down onto the garment(s).

Q: How Long Does The Custom Applique Last On Garments?

A: All of our fabrics have been tested up to 50 wash and dry cycles.

Q: What Is The Average Turnaround Time For Custom Applique?

A: We create an artwork proof of the design and confirm the price and quantity via email, usually within one business day. Once the proof is approved and signed by the customer, the production time is approximately 3-5 business days.

Q: What Kinds of Materials Are Used To Produce Custom Applique?

A: Sports Twill is the most common applique fabric. It is used by all major league and professional sports teams. In addition to Sports Twill, we offer Fashion Fabrics (like Boxercraft), Sports Felt and Metallic Twill as well as Diamond Twill. All of these materials work with each other, so it’s possible to have a combination of colors, fabrics and textures. It is also possible to send in fabrics from other stores and suppliers for adhesive coating and custom cuts.

Q: Can I Get A Proof Sample of My Design Prior To Actual Production?

A: Yes. An artwork proof is generated automatically with your request. Production begins once the proof is approved and signed.

Q: Is There A Minimum Order Quantity or Purchase Amount For Custom Applique?

A: There is a 5 piece minimum for custom applique and price discounts at quantities of 10, 30 and 50+ pieces.

Our Locations

Twill USA has 2 warehouses for fast delivery. Local pickup is available 8:30a–4:30p (M–F)

Aurora Plant

Specialty Adhesive Film Co.
c/o TwillUSA Division
10510 Randall Avenue
Aurora, IN 47001

Phone: (866) 806-9120
Fax: (888) 926-0634

North Las Vegas Plant

Specialty Adhesive Film Co.
c/o TwillUSA Division
1914 Mendenhall Drive
North Las Vegas, NV 89081

Phone: (702) 644-0532
Fax: (702) 644-0530

The Easiest Way To
Buy Heat Transfer
Materials Online.

Our Hours:
8:00 AM—5:30 PM

Eastern Time

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