Jean, there is a product called Gunold Thermofix which is available from a UK company for which I have provided the website link below. Go to applique backings and fabrics, click on applique backings and then Gunold Thermofix. I have used this product without any problems on outdoor garments used in all weathers. Shout...............if you need any more help.
Would Heat and Bond work for the iron-on part?
The hardest part of badges for me is getting the to stay on what you've bonded it to. At a dog show (yes, they have iron-on dog badges too) when I was going to buy a badge, they were doing the iron-on part. They said that some glues need 350º iron temp. Mine only gets to 340º so the badges tend to fall off. I'd suggest stitching around the badge if you want it to survive multiple washings.
I use felt, or any fabric that doesn't fray or ravel. Have fun, Hugs Cheri
There are tutorials for badge making on Urban Threads and Embroidery Library. Is is a particular design she wants or can you choose?
Thanks Sue I'll take a look on there, she wants flowers, that's the easy part, but what to sew it on, Jean xx