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Choosing edge, backing and size for a patch
Patches are worn on the outside of a garment, which makes three decisions matter far more than they do for an inside label: how the edge is finished, how it attaches, and whether the size suits the surface it lands on.
Merrow edge or hot-cut
A Merrow border is an overlocked thread edge sewn around the perimeter — raised, tactile, and the classic badge look. It only follows simple outlines: circles, ovals, shields, rounded rectangles. A hot-cut edge is sealed flush and follows any shape precisely, which is what you need for script logos, mountains, animals or anything irregular.
Backing determines where it can go
Plain backing is sewn on and works on anything. Iron-on bonds to cotton, denim and canvas but not to nylon, coated shells, leather or stretch knits. Hook-and-loop suits patches that need to come off — tactical, workwear and uniform applications where the same garment carries different insignia.
Size to the panel, not the garment
A cap front panel is bounded by seams, so 50–65 mm wide is the practical ceiling. A beanie cuff is narrower still at 40–55 mm. Jacket backs and workwear take far more. Measure the flat area the patch actually has to sit on, because a patch that crosses a seam will never lie properly.
Detail survives better than you expect
Woven patches hold finer detail than embroidery because thread density is far higher than stitch count — small text stays legible where an embroidered version would fill in. That is why woven is the usual choice when a logo has fine lettering, and why color count does not drive the price the way stitch count does.
Read more: Woven patches guide · Merrow vs hot-cut edge · Patches for hats · Iron-on patches
