Heat-cut and laser-cut edges
A heat-cut edge is a patch outline cut with a hot blade or laser after embroidery, sealing the polyester twill as it cuts so the edge does not fray. It follows any shape — letters, mascots, irregular outlines — where a merrow machine cannot. A satin-stitched border inside the cut line usually gives the finished look.
Illustration — not a photograph of a specific order.
From our production data
Of embroidered orders that recorded a border choice, only 0.6% (1 of 179) were recorded plainly as "no border" — heat-cut is almost always paired with an inner satin-stitched border rather than left bare, which is why "heat-cut, no border at all" is the rare case, not the norm, in the recorded rows.
When to choose it — and when not to
Choose heat-cut for any custom outline, small patches, and designs a merrow machine cannot trace.
Skip it if you specifically want the raised rope edge — that finish is merrow only. On chenille and PVC the question does not come up: chenille edges are stitched, PVC is moulded.
Written by Imran Raza, Founder of Panda Patches
13+ years in custom patch manufacturing. Figures on this page come from Panda Patches’ own production records.
Published September 17, 2026 · Last reviewed September 17, 2026
Cite this entry
Source: Panda Patches Glossary — “Heat-cut and laser-cut edges.”
https://www.pandapatches.com/glossary/heat-cut-edge