Laser-Cut Border
A patch edge cut by a CO2 laser, providing extreme precision for intricate shapes and producing a clean sealed edge similar to hot-cut.
Laser-cut borders are produced by feeding finished embroidered patches through a CO2 laser cutter that vaporizes the surrounding material along a programmed path. The laser cuts cleanly through twill, stabilizer, and adhesive layers in a single pass, sealing the cut edge as it goes.
Laser cutting allows for the most intricate and precise patch shapes available: tight inside corners, fine details around the perimeter, very small patches, and shapes that would be impossible to merrow or hot-cut by hand. Custom morale patches, intricate logo shapes, and small detailed designs typically use laser cutting.
The edge appearance is similar to hot-cut: a thin, sealed, slightly darkened line. As with hot-cut, designers often add a satin-stitched border just inside the laser-cut line to give a finished embroidered outline. The combination of laser precision and satin border framing produces some of the cleanest custom patches available.
Laser cutting requires that the patches be designed with the cut path in mind. The digitizer or designer provides both the embroidery file and a separate cut-path file (typically a vector outline) to the laser operator. The laser is programmed with this path, then runs through a tray of patches one at a time or in batches. The process is fast and accurate, which is why most modern high-end custom patches are laser cut.
Examples
- Intricate morale patches with fine perimeter detail
- Small custom logo patches under 2 inches
Related Terms
- Hot-Cut Border →
- A patch edge finished by cutting with a heated blade that seals the polyester fibers as it cuts, producing a sharp clean edge without overlock.
- Merrowed Border →
- The classic thick overlocked edge stitched around the perimeter of a patch, named after the Merrow sewing machine that produces it.
- Twill (patch backing) →
- The woven polyester base fabric that patches are stitched onto, providing a smooth dense surface for embroidery.
- Iron-On Backing →
- A patch backing treatment that adds a heat-activated adhesive layer, allowing the patch to be applied to garments with a household iron or heat press.
- Velcro Backing (Hook & Loop) →
- A patch backing made of hook-and-loop fastener material, allowing the patch to be attached and removed repeatedly from a matching loop panel.
Used in our services
Precision laser-cut patches with sealed edges for intricate custom shapes.
Laser-Cut Patches →