Wes said:
The cafepress store generates virtually no profits for the site. If you buy a $17 shirt, it's likely I'm only getting $1 from that.
Ouch. Cafepress doesn't let you set the prices? places like pikistore and spreadshirt have a base price for their cut, then you determine how much you want to earn from each unit sold.
Also, pricing on bulk orders of patches are pretty cheap if you order them from Asia, though I don't know what the costs are with shipping:
asiapatch
patches direct
This site even gives free shipping:
Butler patches
If a bunch of people are interested in getting more patch designs, I'd totally be willing to chip in for an order. Ordering individual custom patches costs like $80! Whereas buying 50 of the same size in bulk costs like $81, and a hundred for $99....
Though you've been able to go a few years already with 50 patches, it would be cost-effective for like 20 people to put in like $5 each, then just send the rest to you. With that many patches, you could put them up for sale on ebay or something, thus making them available for future purchase, and all the proceeds would go directly to the site. 'Selling' them could possibly be more effective than giving them out as a 'reward' for donating. Psychologically, you'd be spending the money on something you want rather than giving it away.
These are all just thoughts. Obviously having patches would hinge on demand for them. I'm only bringing all this up because I personally just think it would be cool to have all of them on my old army pack and BDUs.