It's easy to get T-shirts with your favorite bands on them, but not so much on a hoodie. A customer specifically wanted this done, so I thought I'd document it in case it was of interest or use to anyone else.
Step 1: Chalk Out, Press Out and Cut Out
Chalk out the design that you want and trim just outside of that line with sharp scissors.
Smooth out fabric with warm iron
This is Heat'nBond Lite. It is similar to double-sided iron-on interfacing, but one side has paper that you later peel off.
I cut a squarish piece of the Heat'nbond the same shape as my design. Shiny paper up, textured glue side down.
Iron on according to instructions. Basically 2-3 seconds per spot, keep moving until done. This bonded the paper to the red jersey.
I then brought it over to the cutting mat and, using a rotary blade, squared up all the edges.
Step 2: Apply
Chalk out exactly where you want your design to go onto the hoodie. Triple-check for perfect alignment.
Peel paper backing of Heat'nbond from jersey and place onto hoodie. It is not sticky, you can adjust it as necessary.
Place a thin piece of muslin or ironing cloth over design and iron according to instructions, about 6 seconds per spot.
After removing muslin I then ironed the edges where there was no silkscreen.
Step 3: Sew Edges
Ironing on does not make it permanent so you still need to stitch the edges down. I chose to use a zigzag stitch to overcast the edges and to give flexibility as it is a stretch knit.
Make sure the needle just clears the edge to contain it through washings.
Pull loose threads through back and tie.
The finished patch
Step 4: Additional Design
This is another part of their logo that wasn't on the T-shirt so I had to design.
I ironed on a piece of Heat'nbond larger than the design I would draw.
I drew on the design, reversed.
Cut out and place onto hoodie to figure where it looks best.
Step 5: Peel, Iron and Paint
Peeled off backing and ironed on, right where the heart is. : )
I lightly penned on the exclamation point, then went over that with a Sharpie.
Let dry, a little heat with the iron and a light coat of Mod Podge. It dries clear with a satin finish.
Step 6: Some More Stitching and All Done!
I narrowed and shortened the zigzag for the heart and went a little slower.
Pull loose thread through back and tie.
Nice and neat, no distortion, will last through washings.