We bought and printed like 6000 patches for a large customer in LA recently. They specifically wanted organic cotton. I found a source in Colorado who was super cool and well priced. We bought a 100 yards of this organic cotton and hemp 12oz canvas (we needed 75 yards, but it was actually cheaper to buy 100 and we still have 25 yards). Then we bought a fabric cutter, cut them into 15x15" swatches, ganged up 8 images (rectangular) on a screen, printed all the swatches, then cut into individual patches. This was way more cost effective than purchasing as many shirts as we would have needed and then cut them up, and the 12oz fabric was way more patch friendly, sewing and cutting and whatnot...