Oh my.
How big is the run, depending on how big the run is, how many different/complex silhouette shapes, the kinda wham bam process is just use a regular embroidery machine, stitch as much as the largest frame can handle with flat twill and use a hot knife to cut and seal the edges (can add or not the heat adhesive on the back side as well, depending on application substrate, just better to do before start stitching). That to me is probably going to be the cheapest, depending on how many one has to do and how many/complex the silhouette is for the patches.