Oh - for a real world prop, not of a computer rendering...
About 6 cm (2 1/2") would look right to me.
BTW: There used to be some really cool, inexpensive paper/transfer/ink stuff for laser printers that might work great for this - I'll do some digging...
Actually, I am going for die cast metal. The first batch would feature a reflective silver sunburst set against black background. Which will be in contrast to the patch - which will be canary yellow and white to symbolize the Navy.
You might look into glass enameling- I'm not sure how expensive it is to get into, but it's what first comes to mind for the project you're describing.
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