The Complete Guide To:
Custom Patch Hats
Make Merch People Actually Want to Wear

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The Complete Guide To
Custom Patch Hats
Custom patch hats are a popular fashion statement for individuals and a powerful tool for businesses to promote their brand. Adding custom patches with a logo or message transforms a simple hat into a branded apparel. Employees can wear them, they can be distributed as promotional items, or even sold as merchandise.
Stylish and practical, custom patch hats offer a cost-effective way to boost brand visibility. They are items people use daily, making them an excellent medium for reaching a wide audience.
This guide explores everything you need to know about custom patch hats for businesses. We’ll cover their benefits, various styles and materials, and step-by-step tips on designing and ordering your custom patch hats.
Pro Tip: Why stop at one service? Mix and match to make a totally unique piece of custom merch. Additionally, if you’re looking to have your custom patch hat consumer ready, finishing services might be right for you.

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Types of Custom Patches for Hats
There are many different types of custom-made patches for hats that businesses can use to enhance their image. Embroidered patches are a classic option that offers a traditional, high-quality look while woven patches are another popular choice, with a finer level of detail and a softer feel. Ultimately, the type of patch you choose for your business depends on your branding goals, aesthetic preferences, and intended use for the patches.

Embroidered Patch Hats
Custom patch embroidered hats are a classic and popular choice for businesses seeking branded apparel. Embroidery enhances the patch with depth and texture, allowing intricate designs and details to shine in logos or messaging. These patches can be applied to various hat styles, including classic baseball caps, trendy custom dad hats, and even beanies.
This versatility lets businesses craft a custom look that resonates with their audience and aligns with their brand identity. Practical and stylish, custom embroidered patch hats make excellent promotional items or employee uniforms. They are durable and suitable for daily wear.
Incorporating custom embroidered patches into your marketing strategy creates a lasting impression on customers while boosting brand recognition. These hats are more than just accessories—they are powerful branding tools.
Sublimated Patches
Custom logo patches for custom hats are an eye-catching and versatile option for businesses to create corporate gifts for employees, branded merchandise or promotional items. With custom sublimated patches, companies can showcase vibrant, full-color designs printed onto fabric patches. These patches offer exceptional detail and stand out, making them ideal for a range of shapes, sizes, and uses.
Whether you’re designing beanies, custom patch trucker hats, or other styles, sublimated patches can be attached to various items like hats, bags, and jackets. This flexibility allows businesses to craft unique products that align with their brand identity and appeal to their target audience.
In addition to their visual appeal, sublimated patches are highly durable and long-lasting. This makes them a reliable choice for custom hat patches designed for frequent use or wear, ensuring your brand stays visible and memorable.


PVC Patch Hats
Custom PVC patch hats are another great way for businesses to promote their brand. These patches are made with a durable and flexible PVC material, which is perfect for creating high-quality patches that can be attached to the hat’s front, back, or side. PVC patches can be designed with a company logo, slogan, or any other message that the business wants to convey.
Ultimately, these patches are not only practical but also stylish, and they can be worn by employees, customers, and fans alike. With custom PVC patch hats, businesses can create a unique and professional look that will help them stand out in a crowded market.
Raised Patch Hats
Custom raised patch hats are a stylish and practical way for businesses to showcase their logo or branding. Various types of raised patches are available, each offering unique aesthetics and benefits. For instance, 3D embroidery creates a textured, elevated effect that adds depth and visual appeal. Leather patches, on the other hand, provide a classic and sophisticated look, making them perfect for timeless branding.
For a modern alternative, rubber patches offer durability and flexibility, standing up to wear and tear while maintaining their bold appearance. Businesses can also choose sublimated raised patches, which use heat transfer technology to produce vivid, eye-catching designs.
Custom raised patch hats allow businesses to create a distinctive, branded look that captures attention and leaves a lasting impression. They combine practicality and style, making them an excellent choice for promotional items or merchandise.


Chenille Patch Hats
Custom chenille patch hats are an excellent option for businesses looking to create a vintage or retro look for their branding. They have a distinct texture and raised appearance and can be used to showcase a company logo or message.
These patches are often used for athletic and letterman jackets, but they can also be attached to hats to create a unique and eye-catching accessory.
Chenille patches can be designed in a variety of colors and shapes, allowing businesses to create a custom look that suits their branding needs. Overall, custom chenille patch hats are a stylish way for businesses to promote their brand while adding a touch of nostalgia to their marketing efforts.
Silicone Patch Hats
Custom silicone patch hats are a unique and modern way for companies to showcase their branding on a practical and durable accessory. Silicone patches can be molded into various shapes, sizes, and designs, allowing businesses to create a custom look that suits their branding needs. These patches are flexible and long-lasting, making them a great option for companies looking to create a high-quality accessory that will withstand wear and tear.
Custom silicone patch hats can be designed with a company logo, slogan, or any other message that the business wants to convey. These custom hats are not only practical but also stylish and can be worn by employees, customers, and fans alike. Overall, custom silicone patch hats are an excellent way for companies to promote their brand while creating a unique and distinctive look.


Rubber Patch Hats
Custom rubber patch hats are a popular option for companies looking to create a durable and modern accessory that promotes their brand. Rubber patches are made of a flexible and sturdy material that can withstand exposure to the elements and daily wear and tear. These patches can be created in various colors and shapes, allowing businesses to customize their design to fit their branding needs.
Custom rubber patch hats can be designed with a company logo, slogan, or any other message that the business wants to convey. These custom hats are practical and stylish and can be worn by employees and customers alike. Overall, custom rubber patch hats are a great way for companies to create a unique and eye-catching accessory that promotes their brand and adds a touch of modernity to their marketing.
Applique Patches
Custom applique patches are a classic and timeless option for companies looking to create a high-quality accessory that showcases their brand. Crafted from layers of fabric, which are cut and sewn together to create a design, these patches can be created in a variety of colors and fabrics, allowing businesses to create a custom look that fits their branding needs. Not only that but they can be designed with a company logo, slogan, or any other message that the business wants to convey.
These patches can be attached to custom hats using a heat-seal adhesive or by sewing for a durable and long-lasting accessory. Custom applique patch hats are not only practical but also stylish, and can be worn by employees and customers.


Tackle Twill Patches
Custom tackle twill patches are a popular and versatile option. The material is made of a combination of fabric and embroidery, which creates a textured and layered effect. These patches can be created in a variety of colors, fabrics, and shapes, allowing businesses to customize their design to fit their branding needs.
These patches can be attached to custom hats using a heat-seal adhesive or by sewing, and they are not only practical but also stylish. Overall, custom tackle twill patch hats are a smart, attractive way for companies to promote their brand while adding a touch of texture and depth to their branding methods.
Leather Patch Hats
A custom leather patch hat is an excellent way for businesses to elevate their brand and make a lasting impression on their customers. High-quality custom leather patches for custom hats can be embossed or debossed with your business’ logo, adding a touch of sophistication to the hat.
Custom leather patch hats are also highly durable and long-lasting, making them an excellent promotional item that will be used and worn repeatedly by customers. Additionally, custom leather patch hats are available in various hat styles, including baseball caps, snapbacks, and beanies, making them suitable for any business or industry. By incorporating custom leather patch hats into their marketing strategy, businesses can increase brand visibility and create a memorable impression on their target audience.

Explore The Most Popular Styles of Hats for Custom Patches
At DTLA Print, you’ll discover several popular styles of hats for custom patches, some of which you’ll find below.
Custom patch trucker hats are a trendy and popular choice that offers a stylish and practical accessory for outdoor or casual wear, making them ideal for employees that enjoy an active lifestyle. With a range of colors, materials, and design options from which to choose, custom patch trucker hats can be customized to fit any brand’s image and message, making them a versatile and effective marketing tool.
Custom patch baseball hats are a classic and versatile option that offers a comfortable and practical accessory for everyday wear, whether it be for employees or customers. With a range of materials and design options available, custom patch baseball hats can be tailored to fit any brand’s image and message, making them a popular choice for corporate swag, giveaways, or as part of a uniform.
This hat style is popular for companies looking to create branded apparel for their employees or customers. These hats offer a stylish and practical way to promote a company while also providing a useful accessory for daily wear. With a variety of colors, materials, and design options available, custom patch snapback hats can be tailored to suit any brand’s aesthetic and marketing goals.
Custom patch golf hats are also an excellent way for companies to promote their brand and create a sense of team unity among employees who enjoy playing golf. Available in several colors and materials, you’ll be surprised at how attractive these hats will look once they’re complete with your company logo or message.
Custom vintage patch hats are a great option for companies looking to create a unique and nostalgic look for their branding. Vintage patches can be sourced from a variety of places, including old jackets, bags, or other accessories. These patches can be attached to hats to create a one-of-a-kind accessory that evokes a sense of history and nostalgia. Custom vintage patch hats are not only practical but also attractive, making them ideal for wear by employees, customers, and fans alike.
Custom logo patches are a popular and effective option that can be designed to feature a company’s logo or emblem and created in a variety of colors, fabrics, and shapes. These patches can be attached to hats using a heat-seal adhesive or by sewing, promoting a durable and long-lasting product. Logo patches are a great way to increase brand recognition and build brand loyalty, as they provide a visible and easily recognizable symbol of a company’s brand.
Popular Products for Customizing Hats with Patches
In terms of custom patch hats, there are several popular options from which to choose. Continue reading to learn more.
Available in either a classic trucker or snapback style, the custom Richardson 112 hat is the perfect jump-off point for any company swag. Complete with attractive colors and plenty of room for nearly any style, material, or size patch you desire. When you explore the collection, you’ll discover features, ranging from a mesh back to adjustable sizing.
North Face is another well-known brand that’s highly sought after because of its expert craftsmanship and rugged durability. The North Face NF0A4VUA Ultimate Trucker Cap is an excellent option for anyone looking to create custom patch hats for their business. Available in a contrasting two-color scheme, this custom trucker hat patch option has a broad front that makes it the perfect base for any style patch. Finally, with a vintage wash, this cap promotes a unique style that will help your company stand out.
The Yupoong 6006 is a classic style trucker hat perfect for many different events, promos, and give aways. Complete with a foam top for either printing or embroidering with high detail, and a mesh back for breathability, it also provides protection from the elements. It comes available in several
colors and boasts a comfortable closure to adjust size that makes it a joy to wear.
Fast & Transparent
How This Process Works
Your account rep will work with our teams to review each and every order by triple checking all details and artwork for accuracy and optimal print quality. You will receive a free full creative proof for your approval before we proceed to production.
3x


Choose Product(s)
- Select product to print on
- Select colors, sizes
- Select print types, locations


Upload Artwork
- Upload artwork file(s) as well as any special instructions
- Your artwork is checked for optimal quality and resolution
- Your account rep will review & guide you through the rest
- Once approved, we’ll begin your order

Make a lasting impression
- Lead the pack in your industry with employees and customers that actually want to wear your merch
Custom Patch Hats
Frequently Asked Questions
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Dimension limitations on custom patches vary depending on the patch type. The minimum dimensions are usually determined by the size of the smallest detail in the design, which should be legible and recognizable when the patch is produced. The maximum dimensions are usually limited by the size of the embroidery hoop or the patch machine itself. Some patch types, such as PVC or silicone patches, may also have limitations on the size of the design or the level of detail that can be included.
Custom patch minimums vary depending on the patch type and the company you order from. At DTLA Print, our order minimum for custom patches is 100. This is because we focus on wholesale & bulk orders to help our clients reach the highest ROI available.
Custom patches for hats can be made in several ways, depending on the patch type and manufacturing process. Here are some common methods:
- Embroidery: Embroidered patches are made by stitching a design onto a fabric base using thread. The design can be digitized from an image or created from scratch using specialized embroidery software. The fabric base is usually a twill or felt material, and the edges are finished with a merrow or overlock stitch to prevent fraying.
- Chenille: Chenille patches are made by layering and stitching chenille yarn onto a felt base. The yarn is then cut to create a plush, textured design. Chenille patches are commonly used for letterman jackets and other sportswear.
- Tackle Twill: Tackle twill patches are made by cutting letters or shapes from a twill material and stitching them onto a felt or other backing material. The edges are then finished with a satin stitch to prevent fraying.
- PVC: PVC patches are made by molding a design onto a flat sheet of PVC material. The design is then cut out and backed with a layer of adhesive, allowing it to be attached to a hat or other item.
- Silicone: Silicone patches are made by molding a design onto a sheet of silicone material. The design is then cut out and backed with a layer of adhesive, allowing it to be attached to a hat or other item.
While custom patches offer many options for companies to create unique and personalized accessories, there are some limitations to keep in mind. First, the size of the patch will ultimately determine the level of detail that can be included in the design. Smaller patches may not be able to accommodate intricate designs or small text. Second, the type of patch material can also limit the design possibilities. For example, silicone patches cannot include as much detail as some other patch types, and chenille patches may not be as suitable for designs with fine lines or small details.
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- 4901 South Santa Fe Ave. Vernon, CA 90058
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Contact Us
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There is a 100 piece minimum to work with a sales rep.
For online orders
Screen Printing: 25 pieces minimum
Embroidery: 3 pieces minimum
Water-based Transfers: 1 pieces minimum
Direct-To-Garment: 1 pieces minimum
Patches: 25 pieces minimum
Office: (323) 261-8700
9 AM - 5:30 PM PST
Chat Available 9 AM - 2 AM PST
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Basic info
Your dedicated account rep is here to keep you updated and offer real time suggestions and project navigation every step of the way. Online ordering and live price quotes available here.
Have you ordered custom apparel & headwear before?
This will help us tailor the experience depending on your experience and know how to best support you.
Which services are you interested in?
Select one or as many of the services below you are interested in.
Do you already know what products you would like to order?
If you need help to identify the correct product for the correct demographic at the correct price point, select "I need help searching" and we will ask you a few additional questions to allow us to submit the best options for your project.
Tell us a little about your target demographic
We want to make sure your recipients will love and wear the merch you create time and time again. These questions will really help us identify the products that will best fit your audience.
Design Included in price
- Embroidery - Up to 4” x 4” or 8k stitches ( standard logo placements, +$1.50 per 1k stitches )
- Screen Print - Up to 15x18” 1-6 Colors, any larger custom quote, would need to see mock up, submit request here ( link to /contact form )
- Digital / DTG - Up to 14x16” ( +$5 for 15x18” )
- Patches - Up to 3.5” x 3.5” ( + $4.35 up to 5” x 5” )
- Waterbased Transfers - Up to 11x15” ( +$4.85 extra for any larger up to 13.5x17” )
Minimum Order Quantity
- Embroidery-3 pieces min.
- Screen Print-25 pieces min.
- Digital / DTG-1 piece min.
- Patches-25 pieces min.
- Waterbased Transfers-1 piece min.
Edit Quantity
Choose Colors & Sizes
Enter your quantity per size
Please make sure that you have reached minimum order quantity for preferred option. MOQ descriptions you can find
Finishing Services
Fold & Poly Bag
DTLA Print has an in house finishing department in its facility with trained individuals to professionally fold and bag your garments. Bags can be provided with customizable options, however we use a 1 mill flat poly bag which can be air sealed or taped shut.
$0.95/Shirt
+ 2 days
Size Sticker
Add a size sticker to the outside of each garment or poly bag to easily identify the size of a garment. Packages do come separated by size how ever many retailers and fulfillment centers do require these stickers.
$0.65/Shirt
+ 2 days
Custom UPC Label
We will print & apply a custom UPC label for any retailer, 3rd party logistics or fulfillment partner you work with.
$0.75/Shirt
+ 2 days
Hang Tag
Incorporating price tickets and hang tags securely with a pin, while offering a diverse array of sizes, colors, and finishes, significantly enhances the perceived quality and overall appeal of your garment. Additionally, not only elevate the garment’s perceived value but also provide essential product information, giving your customers a more informed and satisfying shopping experience.
$1.8/Shirt
+ 14 days
Woven Main Label
Create a fully custom woven main label. Includes the actual label itself and the sewing of the label. We will reach out to discuss the woven label material choices, shapes, and design. Please note this does add extra business days to the production time.
$2.75/Shirt
+ 14 days
Woven Hem Label
Create a fully custom woven hem label. Similar to the main label, this includes the actual label itself and the sewing of the label. We will reach out to discuss the woven label material choices, shapes, and design. Please note this does add extra business days to the production time. Hem labels go anywhere except the neck label of a garment.
$1.85/Shirt
+ 14 days
Design guidelines
Embroidery
Standard Size
4.5” W but larger can be requested
Max Size
Not common, but possible
File Formats
PSD, AI, PDF, EPS, PNG
Max Thread Colors
12
Specialty Threads
Metallic & 3D Puff
File Specs
Scaled to size or larger with transparent background
Screen Print
Standard Size
3” - 12” depending on location
Max Size
15x18” *special request
File Formats
PSD, AI, PDF, EPS, PNG
Max Colors
8
Specialty Inks
3M Reflective, Water-based, Plastisol, Puff, Etc...
File Specs
Scaled to size or larger with transparent background
Digital / DTG
Max Size
15x18”
File Formats
PNG preferred, ( also acceptable; PSD, AI, PDF, EPS, JPG )
Max Colors
Unlimited
File Specs
300 DPI scaled to size or larger with a transparent background
Patches
Max Size
10x13.5”
File Formats
PNG preferred, ( also acceptable; PSD, AI, PDF, EPS, JPG )
Max Colors
Unlimited
File Specs
300 DPI scaled to size or larger with a transparent background
Waterbased Transfers
Max Size
15x18”
File Formats
PNG preferred, ( also acceptable; PSD, AI, PDF, EPS, JPG )
Max Colors
Unlimited
File Specs
300 DPI scaled to size or larger with a transparent background
Upload Design
Upload Mockups
Don’t worry! Every order is triple checked even if it does not look perfect in this demo.
Do you want us to remove the background?
Our new AI tool will remove the background from the image 100% automatically and free.
Max File Size: 15 MB. For any files larger than 15MB please send via wetransfer.com or dropbox.com and share with sales@dtlaprint.com
Order option
We refer to “Blanks” as garments or products with out any decoration, logo, modification, etc... Essentially it is a product that has yet to be customized.
Blanks are typically ordered to test the fit, fabric, & feel but can also be purchased in bulk to customize on your own or be worn blank.
# of Colors
1 Colour
2 Colour
4 Colour
6 Colour
In screen printing, this is a reference to how many different colors are found in your design. We don’t charge for the base layer so only count the different colors you find in your design / logo.
More than 6
We recommend the Digital or Waterbased Transfer Print method for
Position
Tell us where on the garment you would like the specific design or logo and your account rep will create you a proper mock up to ensure that the design is printed as you intended.
Don’t worry if you don’t place it perfectly, we triple review each order to ensure satisfaction.
Front




Back




Left




Right




Neck Label
Decoration Methods Explained
Fabric
Minimums
Photo Quality
Set up Fees
Large Volume
Low Volume
Specialty Inks
Eco-Friendly Inks
Black Ink
Pantone Matching
Color Vibrancy
Wash
Consistency

Screen Printing

Water-based Transfer

Direct to Garment

Embroidery
Patches
Screen Printing
Water-based Transfer
Direct to Garment
Embroidery
Patches
View Fabric + Ink Chart
Any
Recommend 100% Cotton For Best
Any
Any
25-100 pieces depending on # of colors
1 piece
1 piece
3 pcs
25 piece
A-to C+ depending on image
A+
A+
N/A
N/A
Per Color
Free
Free
Included
Included
Price Lowers Significantly
Price Lowers
Price Remains after 1k units
Small drop in pricing as quantities increase
Small drop in pricing as quantities increase
Expensive Initial Set Up Costs
Easy/No Set Up Free Pricing
Easy/No Set Up Free Pricing
Higher per unit price at low volume
Higher per unit price at low volume
Yes
No
No
3D Puff & Metallic Threads
3D Puff & Metallic Threads
Yes
Yes
Yes
N/A
N/A
Most Rich & Dark Blank Prints
Jet Black/100% Black Available
Black Prints Max Out At 90% Vibrancy
N/A
N/A
Yes
Yes
No
N/A
N/A
Best
Amazing Results on Any Fabric
Best on 100% Cotton
Vibrant
Vibrant
A+
A+
A- / B+ Depending on Fabric Blend
A+
A+
A+
A+
A+
A+
A+
Screen Print - Ink Types
Eco friendly inks + screen prints are the true green alternative to screen printing. These inks replace traditional harmful inks and are 100% PVC and phthalate free.
Mostly used for athletic/activewear fabrics such as nylons, spandex, polyesters, rayons, lycra, that have a lot of stretch but can also be screen printed on other blends for different textures. These inks will make your prints stretch with the fabric and do not create cracks or creases when stretched. These should be printed on all sports jerseys, yoga apparel, athletic uniforms, and activewear.
We offer the 3M reflective ink prints as well as a standard reflective print that come in either a water-based (eco-friendly) or plastisol-based ink with the unique ability to reflect once a light source is aimed at the print. Popular uses for this new ink includes police departments, fire departments, E.M.S., and other safety professions. Has recently become extremely popular in the skate, surf, urban, and street apparel industries.
Well known for their soft feel and vibrant colors they produce when printed onto t-shirts and other textiles. When printed water based inks leave no hand feel behind so you can feel the fibers of the garment.
Inks that expands and rises when heated, giving a three dimensional look with a raised feel. Any Los Angeles t-shirt printer can buy inks and print them, but the real beauty and art of screen printing on t-shirts comes when you can mix inks correctly and accurately. Controlling how the puff inks actually puff is one example.
Silk screen t-shirt printing with plastisol is the oldest and most commonly used ink across the market to screen print your custom t shirts. The misconception how ever is that all inks are the same.
Specialty Order Off-Site
Available in both water based and discharge inks. The ink actually cracks in pieces the way you want it to so no two pieces will be alike. Great for vintage washed out looks while still brand new. This is custom silk screen printing at its best.
Specialty Order Off-Site
Perfect for creating custom silk screened T-shirts right here in Los Angeles. High Density inks can be matched to any color and rises in the drying process to create a 3D look. Inks can be raised to your desired height or width and can be printed with other high density inks of different sizes.
Specialty Order Off-Site
Burnout is a special screen printing process we use to removes the cotton fibers from a shirt, leaving only the polyester intact. It's perfect if you want to give your T-shirt designs that really cool see-through look.
Specialty Order Off-Site
Flocking screen printing can add a new dimension to your materials. Tiny particles of fiber are applied to a material with an adhesive, adding a suede-like or velvet texture to the surface. We color the fiber according to your designs, and you end up with products that stand out from the rest.
Water-based. w/ Base
Water-based. w/ Base
Oil Based. w/ Base
Oil Based. w/o Base
High Density
Puff
Stretch
Silicone
100% Cotton
90% Cotton
10% Poly
50% Cotton
50% Poly
Tri-Blends
100%
Polyester
95% Poly 5%
Spandex
What is Tax Exempt
Tax exemption is the reduction or removal of a liability to make a compulsory payment that would otherwise be imposed by a ruling power upon persons, property, income, or transactions. Tax-exempt status may provide complete relief from taxes, reduced rates, or tax on only a portion of items. Examples include exemption of charitable organizations from property taxes and income taxes, veterans, and certain cross-border or multi-jurisdictional scenarios.
*Only orders shipped with in California are charged tax unless a a valid CA resale form is provided.
How fast do you want us to produce your order?
Production time is separate from shipping
If you're in a hurry to receive your order, we offer an expedited service to fast-track the production process. While this option incurs additional charges, it ensures you get your product sooner. However, if time is not a pressing concern, you can stick to our standard production schedule at no extra cost. We believe in providing you with the flexibility to choose the timeline that best suits your needs.