Custom Laser Cut & Die Cut Patches: Made Exactly to Your Shape
Your logo deserves precision.
Whether you call it laser cut or die cut, we use high-accuracy cutting to shape your patch edge-to-edge, no bulky border, no limits. Available for embroidered, woven, and PVC styles.
Why Laser Cut Patches
Traditional merrow borders look fine — but not when your logo has wings, flames, or wild curves.
That’s where custom laser cut patches (also known as die cut patches) come in. Using heat-sealed laser precision, we trim each patch to your exact outline so it never frays.
Every patch goes through our digital proof process, so you see exactly how your cut line and colors will look before we stitch a single thread. You’ll get high quality patches that feel cleaner, thinner, and more premium than stock shapes.
- Heat-sealed edges (no unraveling)
- Works for PVC, embroidered, and woven patches
- Optional Velcro, iron-on, or adhesive backing
- Low minimum order quantity — start at 100 pieces
Product Comparison
| Feature | Merrow Border | Laser / Die Cut |
|---|---|---|
| Edge | Thick stitched rim | Precisely sealed edge |
| Look | Classic & raised | Modern & seamless |
| Cost | Standard | $0.10 per patch |
| Best Use | Round, square, rectangle | Complex or asymmetrical shapes |
Pro tip: “Die cut” and “laser cut” mean the same in patch manufacturing: both deliver your custom patches made to the shape with your exact specifications.
Options
We can laser cut virtually any patch type:
Backing Options
Finish Choices
Matte, glossy, metallic thread, glow in the dark, or reflective.
Our many available options guarantee your patch will be made ot your exact specifications.
Who Uses Laser Cut Patches?
- Tactical & Military Units – detailed emblems that match wings, flags, or division shapes. Very popular for call signs
- Corporate Branding – sleek patches that mirror your logo’s outline for giveaways or uniforms.
- Outdoor Brands – durable PVC or woven edges sealed against rain and abrasion.
- Fashion & Streetwear Labels – die cut silhouettes that look elevated and retail-ready.
- Clubs, Schools & Sports Teams – fun, clean custom shapes that stand out in photos.
Pricing
Our MOQ (minimum order quantity) is 100 patches.
Up to $0.10 extra per patch for laser or die cutting.
All quotes include free digital proofs, no hidden fees, and quick shipping.
How It Works
Trusted by Great Brands
Apparel brands, fire departments, breweries, and sports clubs across the U.S. rely on us for custom die cut patches that match their exact vision.
Get your design cut to perfection.
Upload your art and choose your backing — our specialists reply within one business day.
Price My Patches
Custom patches, labels, pins & more — pricing within 1 business day.
We'll review your project and send pricing options within 1 business day.
Need to add more files? Just reply to the confirmation email.
Reviews
Always do a great job! I have had multiple patches made here and they always come out gorgeous. Lots of detail, high quality, and the prices are always competitive. This is my go-t…
Quick response and detailed quote. Fast delivery. Great experience.
We have had a great experience with Becky and her team. Always quick and great quality patches.
Very fast and efficient as always! 5 star
Satisfied with the product.
From customer service, to receiving the product, every step was painless and easy to work with Becky.
Still have questions?
Gallery
Ready to Start Your Patch Order?
Laser cut or die cut — it’s the same precision that makes your patch look pro.
Get your quote, approve your proof, and wear your logo proudly.
CASE STUDY: Custom Laser Cut Patches: Kastari
In this opportunity, we thought it would be great to show the progression of a patch from sketch, design through final product.
We chose this laser cut patch because it just looks great! It is to our eyes the poster child of the possibilities of laser cut patches the intricate shape and the quality of the detail.
Cut to shape patches can be a little tricky to design, especially those from very intricate designs, as much as we would like to provide every little in-and-out of the design, somethings are just impossible for the machine to do.
Usually you start with the main design, and then you need to add a background, similar to a mat, where the design will be sitting, in this case we used a very subtle white color to unify the design throughout the die cut shape.
Kudos to the production team, as the final die cut patch turned out great.
What’s the Difference Between Die Cut and Laser Cut Patches?
Laser cutting and die cutting are both popular methods of cutting paper and other materials. But what’s the difference between them? And which one is better for your project?
Die cutting is a process where a sharp blade is used to cut material through a stack of material. Laser cutting, on the other hand, involves using lasers to cut through materials.
While the way of getting the job done is different, the result in terms of the final product is the same: A patch that follows your design much more closely than a merrow border would, without the bumpy edge.
When ordering our products, you can use either term and your final product will be the same. No headaches or confusion. 🙂