Re: UPDATED:Custom Nostromo Kane : Kane FINAL HEAD FINALLY!!
Patch for Kane. Ended up hand-painting it on a triangle piece of a white latex balloon so that it can be flexible but also durable. The iron-on route just wasn't working.
Hey tin, that patch looks great- but I feel I should again suggest what I firmly believe to be a better alternative: Custom-printed fabric. I have used two different companies for this, and both have certain strong points. One is called 'Fabric On Demand', and the other is 'Spoonflower'.
I have had extremely tiny detailed images which I created in Photoshop printed on real fabric at both websites, with really impressive results. I just send the .jpg or .bmp file to them, pay with PayPal, and *poof* it comes in the mail.
The cheapest cost is $18.00 for a piece of fabric about 18"x22", and that would be enough fabric to produce a couple hundred patches, both for the UK (Kane) version and the USA (Dallas) patches, after being multiplied in the Photoshop image.
The main advantage is the realism; having the patches made out of real fabric, and sewn onto the suit would be awesome.
I understand if you don't want to take this route though, given the large amount of time and effort you have already invested. On the other hand, doing it this way might actually SAVE you a lot of work, if you decide to sell a bunch of suits in the future. One more good aspect: the printed fabric never wears off, never cracks or peels; the pigment is fused to the cloth at the molecular level.
Just a thought.