I'm in contact with a company called Butler Digitizing right now, they will deliver to Canada (I think it's even free shipping) with a 7 to 10 day turn around (4 day rush) They seem to have the best prices so far.

I'm going to send them a copy of the design for a quote and I'll let you know what they say, but it's looking maybe... $200 american for 100 patches, which isn't too bad.. they also have a minimum order of 50 if 100 is too many. I'll let you know as soon as they get back to me!

I know I'd definately pay $5 for a fully embroidered patch, probably even $6-$8 honestly... it will be totally cool!