One thing to keep in mind is that we get 3" farthest point to farthest point. In making a patch design, you might want to scale it to see 3" on your screen, just to make sure it's looking how you want. For example, once you scale it like that, you can't get outlines on text, and vertical dimension of the above patch design would be perhaps 1".
With that in mind, you might want to increase vertical dimension, move the roundel down and increase its size.
I suppose we could go to 3.5", which would help some.