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[i]Currently long-duration crewmembers are very limited on the number of names they can include on a patch before they fly. This is to minimize the number of patches produced with incorrect names, for instance in case of a shuttle launch slip or crew swap.
The informal policy is that crewmembers can only order and launch with a limited number of patches with the names of the crewmembers that are currently on-board for their expedition (and their own name included). They are not to include names of crewmembers that have not yet flown. That way there won't be hundreds of patches lying around with the wrong names. Once they are on-board, the office orders more patches with the limited names.
Once an expedition is complete, the patch with all the names of crewmembers that were on the expedition is produced. The only downside is that that complete patch did not fly with the crewmembers.
The vendor makes a limited number "pre-production" patches with all the names for approval by the crew. In this case, you saw the only two full-name patches that I know of. These "pre-production" patches were delivered to Russia for the Sokol suits.[/i]
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