This is one of the finished products:
What I need is the part inside the circular label, which is about 3 inches in diameter (not sure what the equivalent is in pixels). When I make them, I actually use powerpoint for the lettering and copy it to paint.net, where the actual patch is inserted with layering and some editing.
Feel free to come up with squadron names, and obvious and caricatured is ok.
I'll post a smaller collection of what I have so you can look for trends or themes. I have already paid homage to squadrons in the Texas Air National Guard and any USAF units with historical ties to Texas.