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Looking for some tips..what's best material to use for making patches and where is best to get them..any help would be appreciated
there are a couple of different ways. if you're making patches from scratch, most people use twill. then you just put a satin stitch around the outside. it won't have the nice merrowed edge, but some people don't mind.

or you can buy premade patches with the merrowed border. you just hoop a big ol' piece of scrap fabric, attach the patches with spray adhesive and stitch directly on them...
 

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For Poly Twill we use Twill USA and for cotton we use Carr Textile. We get the glue backing from AllStitch. We have a Merrow Machine but some patches can't get that stitch because of the shape. We use a satin stitch on poly and then use a heat gun to clean up the edge.
 
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