Why Some Patches Curl and How to Prevent It

https://www.wikimontessori.com/index.php/Embroidered_vs_woven_patches:_which_suits_your_logo%3F

You sew or iron on a new patch, it looks great, and a few washes later the edges start lifting and the whole thing cups like a potato chip. Curling is one of the most common complaints about custom embroidered patches, and it is rarely random