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 and pricing scale. (see bottom of page) This policy is in place for a few key reasons:

1. 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.

2. 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.

3. 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 Style

we have established a minimum order quantity and pricing scale.  (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 Style

we have established a minimum order quantity and pricing scale. (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.

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

 

Now thats explained,

lets go over 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 bold easy 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

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.

Our Simple Pricing Structure

No extra costs for setup, or limitation on colours, or other price increases on style.

This table is Embroidered Badges Under 60mm x 60mm

Size	Qty	Price
Under 60mm x 60mm	0-50	6.50
	51-100	5.00
	101-200	4.00
	400+	3.15

 

This table is Embroidered Badges Under 90mm x 90mm

Size	Qty	Price
Under 90mm x 90mm	0-50	6.75
	51-100	5.25
	101-200	4.25
	400+	3.25

 

This table is Woven Badges Under 60mm x 60mm

Size	Qty	Price
Under 60mm x 60mm	100	1.75
	101-200	1.60
	201-300	1.35
	400+	1.15

 

This table is Woven Badges Under 90mm x 90mm

Size	Qty	Price
Under 90mm x 90mm	100	1.85
	101-200	1.70
	201-300	1.45
	400+	1.25

 

Extras

Item	Price per unit
Add Velcro / Hook Tape	0.15
Add Hook and loop Per patch	0.28