If you're ordering custom patches for the first time, one of the first decisions you'll face is the border style. The two most common options — merrowed and straight (also called flat or laser-cut) borders — each suit different looks and use cases.
A merrowed border is the classic patch look: a thick, rounded stitched edge that wraps around the entire patch. It's created with a merrow (overlock) sewing machine that binds the edge in matching or contrasting thread.
Best for: Traditional patch styles, military and varsity-inspired designs, patches meant to be sewn onto jackets, bags, or uniforms.
Pros: Classic, durable look; edge is reinforced and less likely to fray; works well on rounded or irregular shapes.
Cons: Adds a small visible border around the entire design, which isn't ideal if you want the patch edge to match the exact shape of a logo.
A straight border patch has the embroidery stitched flush to the exact edge of the design, often laser-cut for precision, with no visible overlock border.
Best for: Modern, minimal branding; logos with complex or angular shapes; patches meant to look sleek rather than traditional.
Pros: Clean, precise edges that follow your exact logo shape; modern aesthetic.
Cons: Slightly less durable edge over heavy wear compared to merrowed; can require careful attachment (iron-on backing or sewing close to the edge).
| Feature | Merrowed Border | Straight Border |
|---|---|---|
| Look | Classic, traditional | Modern, minimal |
| Edge shape | Rounded, follows overall outline | Follows exact design shape |
| Durability | Very high | Good, with proper application |
| Best for | Uniforms, jackets, traditional branding | Modern logos, complex shapes |
If your brand leans traditional — team logos, military-style patches, varsity jackets — merrowed borders are the tried-and-true choice. If your logo has intricate detail or an unusual shape and you want a cleaner, more modern presentation, a straight border patch will show it off better.
MDN Designer digitizes and preps patch artwork in both merrowed and straight border styles, production-ready for your manufacturer.
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