Custom Badge Manufacturing

Our process is as simple as 1234

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

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.

Woven

Minimum Order Quantity (MOQ) is x200 badges (no setup fees are charged, however suitable artwork must be provided otherwise a design /setup fee maybe charged) This is the gold standard for badges and it also the best, and most cost effective.

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.

Bullion badges

Minimum Order Quantity (MOQ) is x20 badges (no setup fees are charged, however suitable artwork must be provided otherwise a design /setup fee maybe charged)

Also known as bullion blazer badges and hand embroidered badges, wire badges are traditional in style and are worn mostly by clubs as well as military and naval associations. Our wire badges combine gold, silver and copper bullion wire with silk thread, creating a raised design. All badges are hand sewn with the utmost care and attention to detail, by hand by our craftsmen

Turnaround

Our skilled team will do our best to turn your work around as quick as possible however we do things right and want to do a good job, we dont believe speed is the best measure of a job well done. let us know your timeline and we will work hard to meet deadlines.

Experience

Embroidery is where we began 15 years ago and it's still super popular. Over the years we have mastered this tricky art and trained all of our team to produce high quality work every time. We pride ourselves on our embroidery quality so you know you are in good hands. We are always keeping ourselves up to date with the latest tech and improving our processes.

What 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 Design, hi quality finish, low price point per unit, downside, is high moq
Embroidered design, high end finish, suited to simple clean designs, high price point per unit, low moq

Why Embroidery?

Sometimes it can be tricky to decide between print and embroidery. But ultimately it's about what kind of finish you are after. Embroidery looks very different to print as its thread that is slightly raised. It creates a professional finish that has a texture. Embroidery is best for small logos or designs with detail. Our machines can achieve perfect detailed logos. It's ideal for crests or military logos and even individual names.

Understanding Badge Borders: Simple, Fun and Easy to Follow

When creating a custom badge, the border does much more than tidy up the edges. It frames your design and has a huge impact on how professional your badge looks.

Even the best artwork can look disappointing if the border is too bulky, uneven, or doesn’t suit the shape.

At EmbroideryBadge.uk, we’ve made tens of millions of badges over the past 30+ years. One thing we’ve learned is simple: the right border can make your badge look amazing, while the wrong one can spoil it.

Let’s take a look at the three main types of badge borders.

The 3 Main Types of Badge Borders

Merrow Border

The classic thick stitched edge, perfect for traditional badges and simple shapes.

Satin Stitch Border

A smooth, premium-looking border ideal for modern badges and custom shapes.

Laser-Cut (Borderless)

A clean, minimal finish with no stitched border at all.

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: 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

Best For

Appliqué badges, text-based designs, and minimalist styles.

Which Border Should You Choose?

Choose a Merrow Border if:

You want a classic, chunky edge
Your badge is large
The shape is simple

Choose a Satin Stitch Border if:

You want a premium, modern look
Your badge has curves or custom outlines
You are using heat-seal backing

Choose Laser-Cut if:

You prefer a clean, minimal design
A stitched edge would feel too heavy

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, hi end edge finish, badge edge does not fray.