The patch border, one of the most important aspects of custom patches, is often the most neglected aspect. Additionally, the aesthetic appeal along with the overall look and durability of the patch is determined by the border.

There are many border styles available, however, the merrow edging remains one of the most sought after for professionally finishing patches and providing them with a polished look.

So, how would one determine if the design warrants a merrowed border patch? Do you go for the patch with a merrowed edge, or would an embroidered border be a better fit? This is what this guide intends to address so that the selection of the most suitable merrowed edge for your custom patches can be done in an informed manner.

What is a Merrowed Edge?

A merrowed border, additionally known as merrow edging, is a stitched border that goes around the edges of custom patches, thus preventing fraying while providing durability to the patch.

This method utilizes an overlock stitch known as the merrow edging which encases the patch, and so, in turn, drastically helps in preventing the patch from fraying and increases durability.

Like many names, the merrow border technique gets its name from the Merrow Sewing Machine Company, which pioneered the merrow edge stitch. Due to its effectiveness, merowing has become a standard technique in the patch-making industry.

Key Characteristics of a Merrowed Edge

• Smooth and Raised Border – The merrowed edge gives a clean, professional look with a slightly raised edge.
• Prevents Fraying – It adds extra protection to the patch, ensuring the edges don’t unravel over time.
• Suitable for Simple Shapes – Merrowed borders work best with standard patch shapes like circles, squares, and rectangles.
• Stitched in Any Color – You can customize the merrow edge stitch in any color to match or contrast with your patch design.

Must read: Which Type of Backing is Right For Your Custom Patches?

Merrowed Edge vs. Embroidered Border: Which One is Better?

When deciding on a patch edge stitch, you may wonder how merrowed borders compare to embroidered borders. Each has its unique benefits and works well for different types of patches.

When to Choose a Merrowed Edge:

• If you want a durable and polished border.
• If your patch has a simple and standard shape (like round, square, or oval).
• If you want a defined border color around your patch.

When to Choose an Embroidered Border:

• If your patch has intricate or custom shapes (such as stars, flames, or animals).
• If you want the border to blend seamlessly into the design.
• If you prefer a flat, stitched finish rather than a raised edge.

Patch Shapes That Work Best with Merrowed Edges

Since a merrowed border is stitched around the patch’s edge, it works best with simple geometric shapes. The merrow edge stitch follows the contour of the patch, creating a smooth and even finish.

Ideal Shapes for Merrowed Edges

✔ Circles
✔ Ovals
✔ Squares
✔ Rectangles
✔ Rounded-edge polygons

Shapes That Won’t Work with Merrowed Borders

✖ Stars
✖ Flames
✖ Jagged-edged designs
✖ Extremely intricate shapes

If your custom patch design has a complex shape, consider a heat-cut edge or an embroidered border for a cleaner finish.

Best Patch Types for Merrowed Borders

Not all custom patches are suitable for a merrow edge. Some patch styles work better than others with this border technique.

Best Custom Patch Types for Merrowed Borders

1. Custom Embroidered Patches – These patches have a raised texture, and a merrowed border enhances the overall structure.
2. Custom Chenille Patches – The soft and fuzzy texture of chenille pairs well with the smooth, stitched finish of merrowed edges.
3. Custom Woven Patches – These patches have detailed, high-definition designs that look great with a neatly finished merrow edge.
4. Custom Printed Patches – Printed patches have smooth surfaces, making a merrowed border an excellent way to add dimension.

Patch Types That Don’t Work Well with Merrowed Edges

• Custom PVC Patches – These are flexible rubber patches that don’t require a stitched border.
• Custom Leather Patches – Since leather is a thicker material, merrow hem stitching isn’t the best option.

Custom Sublimated Patches – These patches feature detailed photo-quality prints, which don’t necessarily need a raised edge.

How to Know if a Merrowed Border is Right for Your Patch

Choosing a merrow edge patch depends on several factors, including your patch’s shape, purpose, and durability needs. Here are some key questions to determine if a merrowed edge is the right fit:

1. What is the Shape of Your Patch?

• If your patch is circular, square, oval, or rectangular, a merrow border will work perfectly.
• If your patch has sharp angles, cut-outs, or jagged edges, a merrowed border won’t be the best choice. Instead, a laser-cut or embroidered border may be a better option.

2. Do You Need Extra Durability?

• If your patches will be exposed to wear and tear, such as on jackets, backpacks, or uniforms, a merrow hem can help prevent fraying.
• If your patch is a collector’s item or won’t be used frequently, other border styles might also work.

3. What Type of Fabric is Your Patch Made From?

• Embroidery patches custom designs are perfect for merrowed borders, as the stitching blends seamlessly.
• Custom chenille patches also work well with merrowed edges, giving them a bold and classic look.
• PVC, leather, and sublimated patches don’t typically use merrowed borders because their materials require a different type of finishing.

4. Do You Want a Raised, Defined Border?

• If you want a thicker, more pronounced border, merrowing is an excellent choice.
• If you prefer a subtle, seamless transition from the patch to the garment, an embroidered border might be better.

How Are Merrowed Borders Created?

A merrow edge stitch is applied using a specialized merrow sewing machine, which wraps thread around the patch’s edges. This process involves:

1. Cutting the Patch – The patch is cut into its final shape.
2. Overlocking the Edges – A merrowed border is stitched around the perimeter, encasing the raw edges.
3. Final Finishing Touches – The patch is heat-sealed or ironed to remove loose threads.

The entire merrowing process ensures that the patch remains durable, with a clean and polished look.

(Quick & Easy Guide): How to Remove a Sewn-On Patch from Your Clothes 

Customization Options for Merrowed Edge Patches

When ordering custom patches with merrow edges, you have a variety of customization choices to make them stand out:

1. Thread Color

• You can match the merrow border thread to your patch’s design for a seamless look.
• Contrasting thread colors can make the border pop for a bold effect.

2. Patch Backing

• Iron-on backing allows easy attachment to clothing and accessories.
• Velcro backing makes the patch removable and reusable.
• Sew-on backing ensures permanent placement on fabrics.

3. Patch Size and Thickness

• Standard custom embroidered patches work well with a merrowed edge at common sizes (2-5 inches).
• Thicker patches like custom chenille patches also look great with a merrow border.

Benefits of Choosing a Merrowed Edge Patch

Opting for a merrowed border has multiple advantages:

Adds Extra Durability – The overlocked stitch prevents fraying.
Gives a Professional Look – The raised edge enhances the patch’s appearance.
Works Well with Most Patch Types – Especially with custom embroidered patches and custom woven patches.
Affordable and Long-Lasting – A cost-effective option for bulk orders.

Order High-Quality Merrowed Edge Patches Today!

Now that you understand merrowed edges and whether they’re right for your patch, it’s time to bring your design to life! Patch Makers USA offers top-quality custom patches with expert craftsmanship, premium materials, and endless customization options.

Let’s create the perfect merrowed border patch for your brand, team, or event. Contact us now and get a FREE quote on your custom patches!