My wife got me a flight suit and a name tag, but I don’t know what the best way to attach it would be. My instinct is to attach the patch to the Velcro, but I don’t n ow if it’s meant to iron-on or if it has to be sewn?
Some nametags come equipped with a glue patch, but I believe few fans use the glue due to the mess they can make - and the permanence of the option.
Velcro’s one option, especially if you’re wanting to remove the patches for when you wash the suit. Most folks however sew them straight onto the flight suit, which was how it was done on the props used in the first two films - this option gives you the choice to upgrade the patches in future, swap them out if you want to shift from a GB1 suit to a GB2 suit (or vice versa), or if you need to replace the suit, but want to keep the patches.
Definitely avoid the glue. I upgraded my no ghost patch recently, and had used the iron on glue on the previous one and it was a nightmare to get off!
I’d also recommend avoiding the iron-on option, as most of mine have tended to start peeling off after a short while. Sewing takes a little longer, but it worth it for looks and durability.
Also, the velcro patch placement on most flight suits sits too far away from the zipper, causing pack straps to overlap the name tag, if that’s any concern. 
Our plan is to stitch the name tag to the Velcro so it can be removed to wash. Does anyone have any tips?
The velcro on the suit is in the wrong place and too small. Remove it. The uses a small bead of glue to hold it in place and sew it on
I did a combination of machine, and hand sewing for the look of it.
What was the cleanest way to remove the velcro strip that comes with the suit? Also, did everyone attach the opposite velcro type to the actual nameplate…what is the best method for that?
My preference is to be able to swap nameplates randomly for when I want to be Spengler or…just me!
Either get a thread unpicker, or a scalpel/xacto and cut the threads on the stitching, and then unpick them. Give the fabric a good rub in multiple directions to close up the stitch holes as much as you can, and then chuck it in the wash, and that should mostly close up the stitch holes.
Awesome–thank yoU!