PATCH MAKING
The border is the first thing a customer touches and the first thing that fails. Satin and merrow solve different problems; choose the edge before you choose the artwork inset.
Satin border: clean and controlled
A satin border is a dense column that follows the patch outline. It gives a crisp, modern edge and works well on circles, shields, rounded rectangles and custom silhouettes. It needs a stable outline, enough space for the column, and a fill that stops just under the inner rail.
For a 70–100 mm patch, a 2–3 mm satin border is a practical range. Narrower borders can look mean and may not cover the fill edge; wider borders eat the artwork and add stiffness.
Merrow border: traditional and forgiving
A merrow edge is an overlock finish that wraps the edge with thread. It looks traditional on letters, shields and souvenir patches. It can hide a slightly irregular contour, but it needs a clean cut and enough room for the overlock to sit outside the fill. Deep inside corners are its enemy.
Which one lasts longer?
Both can last a long time when the backing, density and finishing are right. A satin border is easier to control on a simple contour; a merrow edge can be more forgiving on a hand-cut shape. For heavy washing, the backing and the seam matter as much as the border style.
Design rules that apply to both
- Keep 2–3 mm between the artwork and the inner edge.
- Avoid deep notches that the border cannot follow.
- Make the border overlap the fill slightly.
- Check the border at full size, not on a thumbnail.
- Test the finished edge after a wash and a tumble dry.
What to put in the file
Use one clear outer contour, a sensible number of border stitches, and a colour that contrasts with the fill. If the border is the same colour as the background, the patch will lose its shape at a distance. If it is too bright, it will dominate the artwork.
The best border is the one that looks intentional at arm’s length and survives the customer’s washing machine. Test both before you commit a production run.