Thread weight (40wt vs 60wt)
Thread weight is the thickness of embroidery thread; the higher the number, the finer the thread. 40wt is the industry standard for patches — fills, borders and lettering. 60wt is roughly a third finer and is used only where 40wt would crowd: small text, thin outlines, fine detail.
Illustration — not a photograph of a specific order.
From our production data
We run 40wt as standard and switch to 60wt for satin columns 1–1.5 mm wide, which is what small lettering and fine outlines come down to; below 1 mm a stroke won't stitch cleanly in either weight.
When to choose it — and when not to
Leave the choice to the digitizer; specify only if you're matching an existing run.
Don't request a whole patch in 60wt — fills need more stitches to cover and the patch goes stiff. If a stroke needs to be under 1mm, no thread weight will hold it; the design needs to change instead.
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 — “Thread weight (40wt vs 60wt).”
https://www.pandapatches.com/glossary/thread-weight