Start With the Base Cloth, Not the Edge
For many promotional programmes, a 220gsm polar fleece throw is 100% polyester fleece, brushed on one or both sides, commonly supplied in 120 x 150 cm, 130 x 160 cm or 150 x 200 cm sizes. Do not assume all polar fleece is the same construction. Circular-knit, warp-knit and lower-cost weft-knit fleece behave differently at the cut edge. Require the supplier to declare knit construction, yarn type, finished GSM, brushing face, anti-pilling route and heat-setting process before approving the edge finish.
A workable base-cloth specification is 220gsm +/-5% after finishing, finished size tolerance +/-2 cm for promotional throws, diagonal difference not more than 3 cm on a 150 x 200 cm size, and nap direction consistent across the order. For dark colours, request ISO 105-C06 wash fastness and ISO 105-X12 rubbing fastness from the bulk lot, pre-production lot or a comparable recent lot using the same dye route. For outdoor, stadium or school programmes, ISO 105-B02 light fastness is more useful than a generic colour comment.
Edge choice cannot correct unstable fabric. Loose knitting amplifies wavy overlock and blanket-stitch snagging. Poor heat setting increases edge roll after cutting. Heavy brushing sheds fibres into stitch paths and ultrasonic horns. Unstable shade lots make contrast binding or thread mismatch more visible. Before approving any edge, review roll width, cutting marker, nap direction, fabric relaxation time after spreading and the planned outer fold in packing.
Define the Terms Before Quoting
Factory terms vary. Write the construction, not only the trade name. Overlock means a serged edge made by an overlock machine; specify 3-thread or 4-thread. Blanket stitch means a decorative looped perimeter stitch; some factories use the same phrase for a crochet-look machine edge, but loop density, yarn count and snag risk are different. Ask for a photo and a retained 20 cm edge sample when the term is not clear.
Bias binding means a tape folded around the raw fleece edge and stitched through both faces. It may be true bias-cut woven tape, straight-cut polyester tape, tricot binding or self-fabric binding. The PO should state tape composition, finished visible width, stitch type and corner type.
Heat-cut can mean hot-knife cutting, heated wire cutting or CO2 laser cutting. All create a fused polyester edge, but laser cutting can leave darker beads or odour if power and speed are poorly set. Ultrasonic edge finishing means a horn and anvil seal or pattern-weld the synthetic fleece edge. It is not the same as ultrasonic quilting across the blanket body. For related sealed-edge construction issues, see sonic-cut edges on rPET microfleece.
Decision Tree by Order Type
Price-led event giveaway, single-use campaign or donation pack: start with 3-thread overlock if the target is low price and limited washing. Move to 4-thread overlock if the throw will be washed repeatedly, handled in retail display, or packed and unpacked many times before use. Heat-cut may be cheaper, but only approve it after handfeel and wash checks; a hard fused rim is a common complaint on light fleece.
Corporate gift, university store, club merchandise or retail promo: start with blanket stitch or bias binding. Blanket stitch gives visible contrast branding with less tape cost, but raised loops can snag. Binding gives the cleanest framed perimeter, but tape shrinkage, corner bulk and tape colour continuity must be controlled.
Compressed roll pack, belly band, vacuum pack or tight carton programme: avoid bulky blanket stitch and wide binding unless the packed sample passes the dwell test. In our production experience, a balanced overlock usually recovers cleanly after compression because it adds little edge bulk. Treat that as an observation to verify by pack testing, not as a universal rule. Heat-cut saves thickness but can create edge curl. Ultrasonic can pack flat if the seal is not too stiff.
Frequent laundering, rental, airline or institutional use: choose 4-thread overlock or well-set binding, assuming polyester thread of suitable Tex, stable stitch density, compatible tape shrinkage and an agreed laundering protocol. A loose 4-thread edge with poor tension can fail before a properly sewn binding. A useful adjacent reference is blanket quality control inspection.
Comparison Matrix for the Five Options
Use this matrix as a sourcing checklist, not as a ranking. A disaster-relief blanket, a university giveaway and a boxed corporate gift should not use the same edge by habit.
| Edge finish | Typical use on 220gsm fleece | Cost impact | Relative speed | Main risk | Must specify |
|---|---|---|---|---|---|
| Overlock | Economy promotional throws, donation blankets, event packs | Low | Fast | Loose tails, wavy edges, skipped stitches | 3-thread or 4-thread, thread colour, stitch density, tension, corner lock-off |
| Blanket stitch | Decorative contrast edge for clubs, schools and retail-style promo | Medium | Medium | Uneven loop height, snagging, loose tails | Thread Tex or yarn count, loop height, loop spacing, snag limit, tail trimming |
| Bias binding | Premium gift throws, stronger framed perimeter, retail packs | Medium to high | Slow to medium | Twisted tape, puckered corners, tape shrinkage | Tape width, composition, colour tolerance, corner type, seam allowance, shrinkage tolerance |
| Heat-cut | Fast event orders and low-cost fleece where sewing is minimal | Low | Fast once set | Hard melted edge, odour, scorch, curl | Hot knife or laser, melt bead limit, straightness, handfeel approval, wash check |
| Ultrasonic | Clean synthetic edge on selected polyester or rPET fleece | Medium | Medium once set | Weak seal on lofty fleece, shiny compression line, stiff edge | Horn pattern, seal width, peel check, wash check, retained edge sample |
Cost increases come from different places. Overlock cost is thread and machine minutes. Blanket stitch adds thicker decorative yarn, slower handling and more visible QC rejection. Binding adds tape consumption, tape colour control, corner labour and shrinkage testing. Heat-cut saves sewing but needs blade or laser maintenance and scrap control during setup. Ultrasonic may need horn pattern approval, tooling charge for a custom pattern and lower line speed on lofty fleece.
Shared Test Protocols Buyers Can Enforce
Use one edge durability protocol across all five finishes so suppliers cannot hide weak edges behind different test methods. For normal promotional throws, test one pre-production sample and one bulk shipment sample after 3 home-laundering cycles under ISO 6330:2021, normally programme 4N or equivalent normal mechanical action at 40 C, ECE reference detergent or agreed non-phosphate detergent, 2 kg total load with ballast where needed, and line dry or low tumble dry as stated on the care label. For retail, hotel or repeated-use programmes, use 5 cycles at 40 C or 60 C if the care label will allow it.
Record dimensional change to ISO 5077 after conditioning the washed sample flat for at least 4 hours in standard atmosphere or a clearly stated factory condition. Measure length and width before washing and after the final drying and relaxation, not while the blanket is damp or warm from tumble drying. Colourfastness reports for buyer approval should come from an ISO/IEC 17025 accredited third-party laboratory when the result will be used for compliance, tender submission or retailer onboarding. Supplier internal tests are useful for process control but should be labelled as internal.
Compression-pack testing should match the planned pack. For roll packs, strap or belly-band the sample to the approved diameter for 48 hours at room temperature. For vacuum or tight carton programmes, pack at production compression and hold for 72 hours. After unpacking, allow 24 hours relaxation on a flat table before measuring edge waviness, curl and corner distortion. Measuring immediately after unpacking is useful as a handling observation but should not be the final acceptance measurement.
Measure edge waviness by laying a 50 cm steel ruler along the relaxed edge without stretching the fleece. Record the maximum perpendicular deviation from the ruler line. Measure edge curl by placing the throw flat and recording the maximum lift of the edge from the table over a 50 cm length. For visual defect boundaries, photograph pass, borderline and reject examples under the same light, ruler position and camera distance. Keep these photos with the sealed sample set.
Sampling Plan and Defect Severity
For shipment inspection, use ANSI/ASQ Z1.4 or ISO 2859-1, single sampling, normal inspection, General Inspection Level II unless the buyer manual states otherwise. A common starting point for fleece throws is Critical AQL 0, Major AQL 2.5 and Minor AQL 4.0. Tighten the plan for first orders, new edge constructions, high-value retail packs or a supplier with recent corrective actions.
Critical defects include needle or metal contamination, blood staining, mould, chemical odour likely to breach buyer safety rules, sharp hardened plastic or fused beads that can cut skin, and wrong legally required label. Major defects include open edge, broken stitch, skipped-stitch clusters beyond the limit, wrong edge construction, wrong thread or tape colour outside approved tolerance, corner failure, severe waviness or curl outside limit, tape twisting, scorching, ultrasonic seal separation, and packed size failure affecting carton loading. Minor defects include isolated thread fuzz, slight local tension variation, tail length just above tolerance where secure, small but visible tape width variation, or cosmetic edge waviness within the agreed minor range.
Inspection should include measurement of at least 13 pieces for smaller lots and more according to the selected sampling code letter. Inspect all four sides and all four corners on each selected piece. Edge failures are often local; checking only one folded face misses the defects that buyers later see when the throw is opened.
Option 1: Overlock for Cost-Controlled Volume
Overlock is the workhorse for 220gsm polar fleece. A 3-thread overlock is common for basic promotional throws; a 4-thread version gives a fuller and more secure edge but adds thread consumption and a small amount of sewing time. Typical stitch density is 3 to 5 stitches/cm. Polyester sewing thread in Tex 24 to Tex 40 is usually suitable. Heavier thread can look fuller but may make the edge ropey on a lighter 220gsm body.
Use 3-thread overlock when the brief is price-led, tonal edge, light handling, limited wash expectation and no premium retail display. Use 4-thread overlock when the throw will be washed more than a few times, sold loose or on a hanger, handled by consumers before purchase, used in travel or donation programmes, or made from a knit with noticeable edge stretch. The practical decision rule is simple: if edge failure would trigger a return, choose 4-thread; if the throw is a one-event handout and target cost is tight, 3-thread may be enough after sample testing.
The strength of overlock is speed and tolerance. It follows slight cutting variation better than binding and supports large runs with stable output if thread tension and corner trimming are controlled. See overlocked edges for disaster relief fleece blankets; the principles are similar, though a 220gsm throw has a fuller hand and usually needs less aggressive trimming.
Acceptance criteria: stitch density 3.5 to 4.5 stitches/cm unless otherwise approved; no skipped stitch over any continuous 50 cm section; maximum one isolated skipped stitch per full blanket if locked and not open; tail length 3 to 10 mm; raw edge fully covered with no protrusion over 2 mm; waviness after wash and relaxation maximum 10 mm over 50 cm; curl maximum 8 mm lift over 50 cm; corner puckering maximum 6 mm from flat over a 10 cm corner area.
Corner workmanship should be defined. Rounded corners are faster and reduce bulk; miter-look square corners cost more and show tension errors. For overlock, require continuous stitching around the corner or a locked restart with 15 to 25 mm overlap. No loose tail may sit at the corner point. Corner radius should be consistent within +/-5 mm if rounded.
RFQ and PO wording: 220gsm +/-5% polyester polar fleece throw, four sides 4-thread overlock on industrial overlock machine, tonal polyester thread Tex 27 to Tex 40, 3.5 to 4.5 stitches/cm, raw edge fully covered, corners rounded to approved sample, thread tails secured and trimmed to 10 mm maximum. Supplier must retain one approved pre-production sample and send clear photos of all four edges, each corner close-up and thread cone label before bulk cutting. Bulk production may start only after buyer approval of washed and packed sample.
Inspection severity: broken stitch, open edge, missing overlock section, wrong thread colour, raw edge visible beyond stitch line, severe curl affecting folding and any edge opening under light hand pull are major defects. Needle contamination, sharp contamination caught in the stitch, blood or oil staining are critical defects. Slight thread fuzz or tail length 11 to 20 mm may be minor if secure and not visible in retail presentation.
Option 2: Blanket Stitch as a Visible Design Line
Blanket stitch turns a plain fleece panel into a designed item. It works well on school colours, club merchandise, outdoor campaigns and corporate gifts where the edge colour supports the brand. On 220gsm fleece, the decorative yarn must be thick enough to read visually but not so heavy that it cuts into the knit edge. Polyester textured yarn or acrylic-like decorative yarn can be used depending on machine type and target handfeel; approve colour and loop scale under D65 or agreed store lighting.
Specify blanket stitch by loop height, loop spacing and colour, not by name alone. A useful starting point is 4 to 7 mm visible loop height, loop spacing 4 to 6 mm, and loop-height variation within +/-1.5 mm across any inspected 30 cm section. Contrast stitching makes defects more visible, so it needs tighter QC than tonal stitching. If the throw also carries embroidery, print or a woven label, align thread colour with the artwork reference while allowing for the fact that thread, fleece pile and ink reflect light differently.
Acceptance criteria: visible loop height 5 mm +/-1.5 mm; loop spacing 5 mm +/-1.5 mm; no missing loop in any 50 cm section; maximum one loose loop per blanket if it cannot be pulled longer than 10 mm by light hand tension; tail length 3 to 8 mm and locked into the stitch path; edge waviness after wash maximum 12 mm over 50 cm; curl maximum 8 mm lift over 50 cm; no yarn abrasion cutting into the fleece edge after 3 ISO 6330 wash cycles.
Corners are the common failure point. Rounded corners are more reliable for blanket stitch because the loop path stays continuous. Square corners need a defined lock-off method and usually slower sewing. Require no more than 8 mm visible corner bulk, no loop crossing that creates a hard knot, and no gap larger than one normal loop spacing at the turn. Puckering around the corner should not exceed 8 mm over a 10 cm corner area after relaxation.
Cost and MOQ notes: tonal polyester blanket-stitch yarn is usually available with low friction if the mill carries the shade. Custom contrast colours can require dyeing or special purchase, and the MOQ may be tied to cone quantity rather than blanket quantity. Contrast blanket stitch normally increases inspection time and may add lead time if the colour must be lab dipped. Ask whether the quoted price assumes stock yarn or custom-dyed yarn.
RFQ and PO wording: four sides decorative blanket stitch on approved machine type, approved contrast yarn colour, visible loop height 5 mm +/-1.5 mm, loop spacing 5 mm +/-1.5 mm, rounded corners unless buyer approves square corner sample, tails locked and trimmed to 8 mm maximum. Supplier must submit D65 photos of yarn against bulk fleece, 20 cm retained edge sample, washed sample after 3 cycles and packed sample after 48 h roll-pack dwell. Any yarn colour, yarn count, machine setting or corner method change requires buyer reapproval before bulk.
Option 3: Bias Binding for a Framed Retail Edge
Bias binding is the most visibly finished option for a 220gsm fleece throw. It gives a framed perimeter, hides small cutting variation and supports premium presentation. The trade-off is cost and workmanship sensitivity. Binding adds tape material, sewing time, colour control, corner handling and another shrinkage component. A beautiful tape on the pre-production sample can still fail if the bulk tape shrinks more than the fleece.
Binding choices include polyester woven tape, tricot tape, satin tape, cotton-poly tape and self-fabric binding. For most 220gsm polyester fleece throws, a polyester tape is safer than cotton-rich tape because shrinkage is closer to the fleece body. A common finished visible width is 10 to 18 mm per face. Narrow tape looks clean but exposes cutting and feeding variation; wide tape frames the product but adds stiffness and carton bulk.
Acceptance criteria: finished visible binding width +/-1.5 mm from approved sample on each face; tape twist not allowed; maximum local puckering 6 mm over any 30 cm section; stitch line 2 to 4 mm from inner tape edge unless otherwise approved; no missed stitch in any 50 cm section; tape shade within approved lab dip or sealed sample tolerance; after 3 wash cycles, tape differential shrinkage should not create more than 10 mm edge waviness over 50 cm or more than 8 mm corner lift.
Corners need a construction decision. Mitered corners look premium but need skilled sewing and create bulk. Rounded corners are more tolerant and often better for mass promotional production. If mitered, require miter alignment within 3 mm, no open fold, no raw tape end visible, and bar tack or backstitch lock hidden under the fold. If rounded, require a smooth radius within +/-5 mm of approved sample and no tape pleat larger than 3 mm.
Cost and MOQ notes: tape colour is often the gating item. Stock black, navy, grey and white are easier; custom Pantone-matched tape can require dye lot MOQ and extra lead time. Satin tape usually shows needle damage and shade variation more than matte woven polyester tape. Contrast binding changes both price and rejection risk because every width variation and corner pucker is more visible. Confirm whether the quote includes tape lab dip, shrinkage test and spare tape allowance for rejected pieces.
RFQ and PO wording: four sides bound with polyester woven binding tape, finished visible width 12 mm +/-1.5 mm each face, tonal or approved contrast colour, lockstitch sewn with polyester thread Tex 24 to Tex 40, stitch density 3 to 4 stitches/cm, rounded or mitered corners as sealed sample, no twisted tape, no raw tape end visible. Supplier must submit tape lab dip or stock tape card, 20 cm retained bound-edge sample, washed sample after 3 ISO 6330 cycles and packed carton sample using production fold. Tape supplier, tape width, tape colour, stitch type and corner method may not change after approval without written buyer approval.
Option 4: Heat-Cut Edge for Lean Construction
Heat-cutting can work on 220gsm polyester fleece when the fabric has enough synthetic content to fuse cleanly and the buyer accepts a minimal edge. It is not a universal low-cost solution. Lofty brushed fleece, uneven pile height and unstable knit edges can seal inconsistently. Excessive heat creates a hard rim, dark bead, scorch mark or odour. Too little heat leaves fibres loose and the edge can fuzz after washing.
Hot knife generally gives a straight fused cut with lower tooling complexity. CO2 laser gives precise cutting and can handle shaped patterns, but power, speed and extraction must be controlled to avoid browning and smell. For white, pastel or light grey fleece, heat-cut risks are more visible than on navy or black. Buyers should approve handfeel and edge stiffness, not only the photograph.
Acceptance criteria: melt bead width maximum 0.8 mm unless approved; no sharp edge under finger rub; no scorch or brown line visible at 30 cm viewing distance under D65 light; no burnt odour after 24 h airing; straightness deviation maximum 5 mm over 50 cm; edge waviness after wash maximum 12 mm over 50 cm; curl maximum 10 mm lift over 50 cm; fibre shedding from edge not visibly worse than approved sample after 3 wash cycles.
Corners should be rounded rather than sharp points for most heat-cut fleece throws. Sharp square corners concentrate a hard fused bead and can feel unpleasant. Require radius consistency within +/-5 mm, no molten lump above 1 mm high at the corner, and no brittle fused point. If the buyer needs square corners for a folded retail look, approve the exact cut profile and handfeel on a sealed sample.
Cost and MOQ notes: heat-cutting can reduce sewing cost, but setup scrap should be expected while blade temperature, laser speed and cutting stack height are tuned. Laser cutting may add machine cost but reduce manual trimming on shaped panels. Low MOQ is possible when using standard cutting paths; custom shapes, logos or perforated patterns add programming and approval time.
RFQ and PO wording: four sides heat-cut by approved hot-knife or laser process, cut profile and corner radius as sealed sample, melt bead not more than 0.8 mm, no sharp rim, scorch, smoke odour or brittle corner. Supplier must submit close-up photos of edge and corner, handfeel approval sample, washed sample after 3 ISO 6330 cycles and packed sample after 72 h carton compression if tight packing is used. Cutting method, blade temperature range, laser setting range, stack height and packing method may not change after sample approval without buyer reapproval.
Option 5: Ultrasonic Edge for Selected Synthetic Fleece
Ultrasonic finishing can create a clean, flat synthetic edge, but it is sensitive to fabric construction. It works best where the polyester structure can melt and bond consistently under the horn. A lofty, heavily brushed 220gsm fleece may not seal evenly because the pile compresses before the base knit bonds. The result can be a shiny hard line on the face and weak fusion inside the edge.
Do not approve ultrasonic edges by visual appearance alone. Check seal width, peel resistance, handfeel, edge stiffness and wash durability. A decorative horn pattern may look neat in a showroom sample but become stiff on a full-size throw. If the edge touches the neck, face or hands during use, buyer approval of softness is part of the specification.
Acceptance criteria: seal width 3 to 8 mm as approved sample; continuous bonded line with no unsealed gap over 5 mm in any 50 cm section; no shiny crushed band wider than approved sample plus 2 mm; no hard ridge judged unacceptable against sealed sample; straightness deviation maximum 5 mm over 50 cm; waviness after wash maximum 10 mm over 50 cm; curl maximum 8 mm lift over 50 cm. For a simple shop-floor peel check, the sealed edge should not open more than 5 mm when a 2 cm edge tab is pulled firmly by hand; for enforceable lab testing, define a strip peel method with the test lab before PO release.
Corners must be designed into the horn path. Rounded corners are usually safer than square ultrasonic corners because the horn maintains contact more evenly. Require no unsealed corner point, no melted lump above 1 mm, and no sharp edge. If a pattern horn is used, pattern continuity at corners should match the approved sample within 5 mm.
Cost and MOQ notes: standard straight ultrasonic sealing has moderate setup cost. Custom horn patterns, logo-like edge embossing or special widths may require tooling charges and lead time. Ultrasonic line speed may be lower on brushed fleece because too much speed weakens the seal and too much pressure hardens the edge. Confirm whether tooling cost is amortised in the unit price or charged separately.
RFQ and PO wording: four sides ultrasonic sealed edge on approved horn pattern, seal width 5 mm +/-1.5 mm, rounded corners, no sharp rim, no unsealed gap over 5 mm per 50 cm, edge handfeel equal to approved sample. Supplier must submit 20 cm retained ultrasonic edge sample, close-up horn-pattern photos, washed sample after 3 ISO 6330 cycles and packed sample after production compression. Horn pattern, anvil, pressure setting range, line speed, fabric brushing level and cutting method may not change after approval without buyer reapproval.
Do Not Approve the Pre-Production Sample If You See These
Reject or rework the pre-production sample before bulk cutting if it has a hard fused rim, sharp ultrasonic ridge, scorch marks, smoke or chemical odour, skipped stitches, open edge, loose tails, tape twisting, visible raw tape end, thread or tape shade mismatch, excessive curl, edge waviness after relaxation, corner puckering, corner knots, brittle heat-cut points, unsealed ultrasonic gaps, or stitch tension that tunnels the fleece edge.
Also reject samples that pass visually but fail the pack test. A throw that looks flat before compression can develop permanent edge waves after 48 to 72 hours under a belly band, vacuum pack or tight master carton. For retail programmes, inspect the sample after it has been packed in the exact belly band, ribbon, pouch, PDQ or carton proposed for bulk shipment. Packing is part of the edge specification, not a separate cosmetic step.
RFQ Checklist for Buyers
Put the edge finish into the RFQ, not only into later sample comments. Minimum RFQ fields should include fabric GSM and tolerance, knit construction, brushing face, finished size, edge finish, machine type, thread or tape specification, stitch density or seal width, corner type, colour standard, washing requirement, packing format, inspection plan and change-control rule.
For sewn edges, request thread composition, Tex range, colour source, stitch density, tail limit, lock-off method and whether contrast thread changes price or lead time. For binding, request tape composition, finished width, tape colour MOQ, tape shrinkage data, corner method and tape supplier continuity. For heat-cut, request cutting method, approved handfeel limit, bead width limit and odour control. For ultrasonic, request horn pattern, seal width, tooling cost, peel check and suitability confirmation for the exact fleece construction.
Sample retention should be explicit: one sealed pre-production sample at buyer side, one at factory QC, and one retained by the production line or final inspection team. Approval photos should show full blanket, each edge type close-up, all four corners, thread or tape colour under D65 light, packing method and carton loading if carton compression affects the edge. Require the supplier to label photos with date, sample version, fabric lot and edge setting where practical.
Use Incoterms carefully. Under FOB Ningbo or FOB Shanghai, the supplier controls inland packing and export carton condition until loading. Under EXW, the buyer or forwarder may affect compression and handling earlier. Under DDP or CIF, clarify whether packing-test failure, carton crush or edge deformation after long dwell is part of supplier responsibility. For lead-time planning on promotional fleece, see custom blanket lead times and shipping.
Final PO Clause for Edge Finish Change Control
Use direct change-control wording on the purchase order: supplier must notify buyer in writing and obtain buyer reapproval before changing fabric construction, yarn type, GSM, brushing level, anti-pilling finish, heat-setting route, cutting method, thread brand, thread Tex, tape supplier, tape width, tape colour, ultrasonic horn pattern, ultrasonic pressure or speed range, heat-cut method, corner construction, folding method, packing compression, polybag, belly band, carton size or carton loading pattern after sample approval.
A practical final clause is: bulk goods must match the sealed approved sample and approved test protocol. Any unapproved change affecting edge appearance, handfeel, durability, packing recovery or wash performance is grounds for rejection, rework or commercial claim. Final inspection shall follow ANSI/ASQ Z1.4 or ISO 2859-1, single sampling, normal inspection, General Inspection Level II, Critical AQL 0, Major AQL 2.5 and Minor AQL 4.0 unless otherwise agreed in writing.
Frequently asked
Is 3-thread overlock acceptable for a 220gsm polar fleece throw? Yes, for price-led promotional throws with limited wash expectations and tonal thread. Use 4-thread when the throw will be retail displayed, repeatedly washed, handled often, or made from a stretchy knit edge. Specify stitch density, tail length and skipped-stitch limits either way.
What is a fair skipped-stitch limit for overlocked fleece edges? For normal promotional quality, allow no skipped stitch over any continuous 50 cm section and no open edge. One isolated skipped stitch per blanket may be acceptable only if it is locked, does not open under light hand pull and is not on a visible retail-facing corner.
Can heat-cut edges replace sewing on polar fleece? Only on suitable polyester fleece and only after handfeel, odour, wash and curl checks. Lofty brushed fleece may fuse unevenly. Reject hard rims, scorch marks, brittle corners and smoke odour. A typical melt bead limit is about 0.8 mm unless the approved sample defines otherwise.
What should buyers test before approving ultrasonic fleece edges? Check seal width, unsealed gaps, edge stiffness, handfeel, wash durability and corner bonding. Visual appearance alone is not enough. For 220gsm brushed fleece, require a retained 20 cm ultrasonic edge sample plus a full washed and packed pre-production sample.
Which edge finish is best for a premium retail fleece throw? Bias binding usually gives the cleanest framed retail look, but it needs tape shrinkage control and careful corners. Blanket stitch is a good decorative alternative when contrast colour matters and snag risk is acceptable. Overlock is more cost-efficient but less premium visually.
What inspection standard should be used for edge defects? Use ANSI/ASQ Z1.4 or ISO 2859-1, single sampling, normal inspection, General Inspection Level II as a common starting point. Many buyers use Critical AQL 0, Major AQL 2.5 and Minor AQL 4.0 for fleece throws, adjusted for retailer requirements and order risk.
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