Big Enhancements in Embroidered Patches Due to Die-Cut Edges

Author: chadeg0hst | Posted: 02.12.2011

The process of making embroidered patches has changed very little during the last several hundred years, at least in regards to the principles used. While it's true that materials have changed, more intricate designs have been introduced, and the industry has been highly computerized, an embroidered patch is still functionally similar to what was in earlier times.

On the other hand, one significant development in the industry took embroidered patches one stage further and has allowed for a few of the great contemporary designs we see today. What is this advancement, I hear you ask?

The answer is die-cut borders.

You may have noticed that embroidered patches are no longer limited to coming in shapes that include circles, triangles and squares and this is thanks to die-cut borders. In today's times it is possible for patches to be made in any shape you can think of. So you ought not be surprised to see embroidered patches shaped like transportation vehicles, household items, animals or even caricatures of people. If we didn't have die-cut borders on patches then we would not have the ability to have many of the patches that we see today.

What's The Deal ?

Knives or commercial grade scissors were what was used to cut patches in the days before die-cutting was introduced. It didn't matter that this method left the edges looking quite rough because this was soon neatened up by the embroidering. On the other hand , this cutting method wasn't conducive to unusual shapes because it was too time-consuming, inefficient, and nearly impossible to find a sharp looking border. Die cutting changed all of that when it eliminated the need for hand cutting.

Die cutting works by placing large pieces of patch material on a table, then cutting out individual pieces by pressing a prefabricated die through it. The shaped pieces are separated from the large piece of material by the die which contains very sharp blades around the edges. The die is also shaped exactly as the manufacturer wants the finished patch to look. It could be considered similar to a giant cookie cutter and that has been mounted on to a computerized machine that will cut through the patch material.

The Key Benefits Of Having Die-Cut Borders

As earlier mentioned, die-cut edges offer the possibility of more intricate shapes with more detailed embroidery. In addition to that, die cut borders will last longer than hand cut borders and they are able to withstand temperature changes and washing. When these patches are applied using heat activated glue, they have a tendency to stay put much longer and don't usually curl up at the edges. In fact, die-cut edges allow glue to cover the entire patch so that when it is applied, even the edges stick to the material.

When the edges are cut the standard way, it is not unusual for the embroidered to unravel over time. With a die cut-edge there is absolutely no embroidery work to come unraveled, so your patch looks much better for a longer period of time.

There really has been a large advancement in the patch making industry as a consequence of die cut borders. We wonder what the next great development will afford the embroidered and military patches industry.

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