Custom badge manufacture at Hanger 39
Custom Badge Manufacture

Premium Woven & Embroidered Badges

From concept to finished product — high-quality custom badges manufactured with precision. Trusted by organisations, brands, and military units worldwide.

200+
Min. Woven
30+
Min. Embroidery
3
Border Styles
Quality Guaranteed
Fast Turnaround
Pantone Matching
Dedicated Support
No Setup Fees*
How It Works

Our process is as simple as 1-2-3-4

4 step badge manufacturing process at Hanger 39
Watch

Badge Manufacturing in Action

Order Requirements

Understanding Our Minimum Order Quantity (MOQ) for Badges

Here at Hanger 39, we are committed to providing high-quality badges at competitive prices. To achieve this, we have established a minimum order quantity of 200 badges. This policy is in place for a few key reasons:

Cost-Effectiveness

Producing badges in larger quantities allows us to optimize our manufacturing processes. This efficiency translates to lower costs, which we pass on to our customers through affordable pricing.

Quality Assurance

By focusing on larger batches, we can maintain consistent high quality in every badge we produce. This ensures that every piece you receive meets our stringent standards.

Economic Considerations

In today's challenging economic landscape, it's more important than ever to balance quality with affordability. Our MOQ is a critical part of this balance, helping us to provide the best value to all our clients.

Embroidery

MOQ: 30

Minimum Order Quantity (MOQ) is x30 badges (no setup fees are charged, however suitable artwork must be provided otherwise a design /setup fee maybe charged) Not all badges are suitable for embroidery as it has its place and limitations.

We understand that every project is unique, and we are more than happy to discuss how we can best meet your specific needs within this framework. Our team is dedicated to working closely with you to ensure that your order not only meets but exceeds your expectations.

Comparison

What's the difference between Woven & Embroidery badges?

The advantage of a woven badge over against an embroidered badge is that you can fit in a lot more detail within a woven patch. This applies especially where there is smaller lettering and intricate detail in the design. The difference price wise between either option is woven is more cost effective where larger quantities are. On a woven patch you can see there is a sharper definition of the design as compared with embroidery. Both are machine made and both have their own appeal depending on the application. Embroidered badges have that raised feel which tends to be regarded as more traditional artform.

The other difference technical between woven and embroidered is that finer threads are used in the weaving process whilst thicker threads are used on embroidery machines. Their are closer matches available to pantone colours, probably more so with weaving than embroidery, however, in any case colour matching can be alot more accurate than traditional embroidery.

Woven badge example showing high quality finish

Woven Badge

  • Woven Design, hi quality finish
  • Low price point per unit
  • Downside: high MOQ
Embroidered badge example showing high end finish

Embroidered Badge

  • Embroidered design, high end finish
  • Suited to simple clean designs
  • High price point per unit, low MOQ
See The Detail

Woven vs Embroidery Close-Up

Border Options

Now that's explained,

let's go over the 3 main types of badge borders

1. Merrow Border

The Traditional Classic

The Merrow border (also known as an overlocked border) is the thick rounded edge you'll often see on military, scout, and vintage-style patches.

It wraps thread around the entire edge, so the border is visible on both the front and back.

Why People Love Merrow Borders

  • Bold and traditional appearance
  • Extremely durable
  • Great for larger badges (70mm and above)
  • Perfect for simple shapes like circles, squares, and shields

Things to Consider

  • Creates a small overlap point or "bump" where the stitching starts and ends
  • Too thick for small badges
  • Not suitable for detailed or unusual shapes
  • Can be less effective with heat-seal backing

Best For: Classic patches, uniforms, and retro-inspired designs.

2. Satin Stitch Border

Popular

The Premium Choice

The satin stitch border is our most popular option for high-end badges.

Instead of being added separately, it is stitched directly as part of the embroidery, creating a neat and polished finish.

Why Customers Choose Satin Borders

  • Smooth and elegant appearance
  • No visible bump
  • Works beautifully on complex shapes
  • Excellent for heat-seal backing
  • Gives a premium, professional look

Things to Know

  • The clean finish is mainly visible from the front
  • The back does not have the wrapped look of a Merrow border

Best For: Streetwear, branded merchandise, corporate badges, and custom-shaped patches.

3. Laser-Cut (Borderless)

The Minimalist Look

Sometimes the best border is no border at all. With laser cutting, the badge is cut precisely to the shape of your design for a sleek and modern finish.

Why Borderless Badges Stand Out

  • Ultra-clean appearance
  • Works with almost any shape
  • Perfect when a stitched border would look bulky

Things to Consider

  • Woven badges may fray over time without a protective border
  • Best when the design naturally supports a borderless finish
Machine embroidered edge with heat sealed edge example

Heat-Sealed Edge

Machine embroidered edge, with a heat sealed edge, can get complex shapes, these are not a high end finish and they are prone to fraying.

Merrow machine finished overlocked edge example

Merrow Overlocked Edge

Merrow machine finished, overlocked edge, hi end edge finish, badge edge does not fray.

Final Overview

See All Border Types Together

Ready to Start Your Order?

Get in touch with our team to discuss your badge requirements. We'll guide you through the best options for your project.