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Updated Drawing & Crafts
Fabrics that don't work well with iron-on alone: nylon, leather, and some waterproof or technical fabrics either can't handle the heat needed or won't bond properly with the adhesive. For those, sewing the patch on, or using a fabric glue rated for that material, is more reliable.
Making it last longer: even a well-applied iron-on patch benefits from sewing around the edges afterward, especially on items that get frequent washing or friction (backpacks, jackets), since the heat bond alone can loosen over many wash cycles.
Washing afterward: turn the garment inside out and wash on a gentle cycle to reduce direct friction on the patch edges, which is where an iron-on bond typically fails first.
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