Die Cut & Laser Cut Patches…What are they?

When choosing the appropriate custom patch style, sometimes you hear: laser cut patches and die cut patches, what are they exactly? And how are they different from merrow border.

Die-Cut Border vs Merrow Border

Basically, when manufacturing a custom made patch, the edges need to be sealed in order for the patch to keep its shape, and be resistant to the different conditions it will be in.

To achieve this, you have 2 options.


Having a border at the end of your patch, like this one, which is called merrow border


Having your patch’s edges laser cut to its custom shape.

As you can see, there is no sewn border on these patches, and it dependes on the look and feel you want them to have. Having your custom made patch laser cut will add only 10 cents per patch to your price.

Making Die Cut Patches is Easier with US by your side!

Die Cut Patches can be made in any size, shape, material, colors… hundreds of combinations that will help you in creating the right custom made patch for your club or organization.

You can have a laser cut border added to:

Embroidered Patches
Woven Patches
Printed Patches

Customer Reviews

4.8/5 – Based on 1102 Reviews

  • Embroidered Patch
    55 out of 5 stars
    "Always a quality product and reordering is VERY easy!"
  • Woven Patch
    55 out of 5 stars
    "Excellent customer service excellent product, They work to make things right even though it was the customers screw up. Paragon of excellence."
  • PVC Patch
    55 out of 5 stars
    "Great Prices, Fast Service, Fast Shipping, No Funny Business, What you see is what you get. They price they quote is the price we paid. Do Business Here!"

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.

laser cut patches
Patch perfectly cut with a laser cut machine
Laser cut embroidered patch

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. 🙂

Let’s Get Started

If you are thinking about ordering your custom products, just click on the button below, our expert Sales Reps will get back to you within 24 business hours and guide you through every step of the process.

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