Embroidery is an art, and inherent in art is the possibility of imperfections. Embroidery is not the same as printing where a design can be copied 100%. Embroidery is a completely different medium, and even the weather can make differences in the final sew out. These differences are slight, but again because embroidery is a completely different medium, there will be slight differences. However, this is why we send you a mock-up sample and sewn out sample via email before we begin final production. Only after you confirm the sew out, will we begin final production. The final production will look exactly like the sew out that you approve.
In addition sewing takes more time, and if you take your patch to a tailor to sew, it will cost you anywhere from $.50 to $3 per garment. The extra $.10 you spend on an iron on option, can save you time and money, and the patch will stay on, just as well as it would if you were wearing the patch.