Patch Edges 101: Merrowed vs Laser-Cut

Choosing the right edge is half the battle. It affects shape options, thickness, comfort, durability—and price. Use this guide from OnlyPatches.eu to pick the edge that matches your garment and logo.

✅ Free help: Get a free edge recommendation from OnlyPatches.eu (upload your logo + garment photo on the quote form).

TL;DR — Quick comparison

Not sure which suits your logo? Ask OnlyPatches.eu for a free edge recommendation.

Merrowed Edge (Overlock)

A thick stitch wraps around the patch, sealing the fabric and creating a classic badge look.

Pros

• Iconic, tactile border for varsity/outdoor/club vibes
• Edge takes scuffs, protecting the design
• Forgiving—hides tiny cut irregularities

Cons

• Shape limits: prefers rounded geometry; sharp inside corners aren’t possible
• Bulk: ~3 mm at the rim can feel chunky on thin tees
• Border wrap can cover micro-details placed too close to the edge

Best on: beanies & knit caps, denim/varsity jackets, round/oval logos

OnlyPatches.eu tip: If your design is a circle/oval and you want a cozy badge feel (especially on beanies), go merrowed.

Laser-Cut (Heat-Cut) Edge

The patch is cut to shape with a laser/hot knife. The cut seals fibers for a smooth, flat edge.

Pros

• Unlimited shapes: sharp points, micro-notches, inner holes
• Slim profile: sits flatter on sleeves, chest logos, tech fabrics
• Art can run right to the edge for a modern, crisp look

Cons

• No padded rim; the look is sleeker, not “chunky”
• On very fuzzy garments, the flat edge can pick up lint (easy lint-roll fix)

Best on: performance wear, uniforms, backpacks, small patches

OnlyPatches.eu tip: If your Illustrator outline has sharp corners or cut-outs, laser-cut is the right call.

Shape Limits (design first, edge second)

• Merrowed: circles/ovals/rectangles/rounded shields; min corner radius ~3–4 mm; no inner cut-outs.
• Laser-cut: anything goes—stars, triangles with sharp tips, logos with internal holes.

How Thick Will It Feel?

• Merrowed: ~2.5–3.5 mm at the rim (soft, protective)
• Laser-cut: ~0.5–1.5 mm (base-dependent)

Garment feel

• Beanies & cuffs: merrowed’s cushion feels premium
• Tees, sleeves, performance gear: laser-cut keeps it sleek

Backings that pair well

Both support sew-on, iron-on (heat-seal), Velcro®, and adhesive.

• Merrowed + Velcro® → easy grip, uniform/tactical uses
• Laser-cut + Iron-on → quick installs on flat cotton/poly
• Nylon/softshell → prefer sew-on or Velcro® (heat-sensitive)

• OnlyPatches.eu can test a sample on your actual fabric and advise settings.

Durability & Care

• Both edges are wash-durable when applied correctly.
• Inside-out washes help; avoid max-heat tumble for iron-ons.

What to photograph for your PDP / lookbook

1. Beanie side-by-side: merrowed round vs laser-cut triangle
2. Denim chest: merrowed shield vs laser-cut sharp logo
3. Macro + ruler: show edge thickness & texture

• (Alt text each image for SEO: “merrowed edge macro”, “laser cut patch edge macro”, “merrowed vs laser cut on beanie”, etc.)

Designer checklist (save a revision)

• Provide vector art + a separate cut line (0.5–1 pt).
• For merrowed, keep key details ≥2 mm inside the border wrap.
• For laser-cut, leave a 1.5–2 mm safe area inside the cut line.
• Unsure? OnlyPatches.eu can mock up both edges at your target size.

Why brands choose OnlyPatches.eu

• Edge expertise: embroidered, woven, sublimated, and PVC patches with either edge style
• EU-based seller: smooth communication & shipping across Europe
• Practical advice: we’ll recommend edge, backing, and size based on your garment and use case

Ready to decide?

• Upload your logo + garment photo and get a free edge recommendation from OnlyPatches.eu