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The Complete Guide To:

Make Merch People Actually Want to Wear

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The Complete Guide To
Custom Patch Hats

Custom patch hats are not only a popular fashion statement for individuals, but they also offer businesses a unique opportunity to promote their brand and increase visibility. By adding custom patches with their logo or messaging, businesses can create a branded product that can be worn by employees, given away as promotional items, or sold as merchandise. 

Not only are they stylish, but custom patch hats provide a cost-effective way to reach a wide audience while providing a practical item that people can use daily. In this guide, we’ll dive into the world of custom patch hats for businesses, discussing the benefits, different styles and materials, and how to design and order your own 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. 

Custom patch hat with Coors logo

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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.

Custom embroidery hat with Texas World Speedway logo

Embroidered Patch Hats

If you’re interested in custom patches for hats, custom embroidered patch hats are a classic and popular choice for businesses looking for branded merchandise. Embroidery adds depth and texture to the patch, allowing for intricate designs and detail to be included in the logo or messaging. Not only that but they can be created using a variety of hat styles, ranging from classic baseball caps to trendy dad hats, beanies, and more. 

This versatility allows businesses to create a custom look that will resonate with their audience and align with their brand identity. Custom embroidered patch hats also make excellent promotional items or employee uniforms, as they are both practical and stylish and can be worn daily. By incorporating custom embroidered patches for hats into your marketing strategy, your business can create a lasting impression on its customers while increasing brand recognition.

Sublimated Patches

Custom logo patches for hats are a versatile and eye-catching way for businesses to create branded merchandise or promotional items. Using custom sublimated patches, your company can enjoy a full-color design that is printed onto a fabric patch, providing a vibrant and detailed image that stands out. Custom sublimated patches can be created in a range of shapes and sizes and can be attached to a variety of items, including hats, bags, jackets, and more, making them ideal, no matter if you’re designing beanies, custom patch trucker hats, or something else entirely. 

This versatility allows businesses the freedom to create unique and custom products that align with their brand identity and target audience. Additionally, sublimated patches are highly durable and long-lasting, making them an excellent choice for a custom hat patch that will be used or worn repeatedly. 

Custom sublimated hat with BC Outdoors logo
Custom PVC patch with Beta logo

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 popular way for businesses to showcase their logo or branding on a stylish and practical accessory. There are various types of raised patches that can be used, such as 3D embroidery, which gives a textured and elevated effect. Another option is the use of leather patches, which offer a classic and sophisticated look. 

Rubber patches are a modern alternative, with a durable and flexible texture that can withstand wear and tear. Additionally, businesses can opt for sublimated raised patches that use heat transfer technology to create a unique and vivid design. Overall, custom-raised patch hats are an ideal way for businesses to create a distinctive look while promoting their brand.

Custom raised patch with Ford Bronco logo
chenille patch

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 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.

Custom rubber patch with SEC logo

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 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 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.

Custom patch hat with Pabst logo applique patch
Custom tackle twill patch with Lacoste logo

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 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 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 company swag, giveaways, or as part of a uniform.

This hat style is popular for companies looking to create branded merchandise 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 is the perfect jump-off point for any company merch. 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.

The AS Colour 1109 Billy Cap is another classic, popular option that is both high-performance and fashionable. In turn, it’s an excellent option for companies that do business in warm climates and looking for a range of more subtle neutral colors. This handsome hat has a low profile snapback cap back, Adjustable plastic fasteners, eyelets, tonal under-bill lining, and a seam free front panel . Constructed from 100% cotton, this hat is both durable and easy to clean regularly.

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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.

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Your order is triple checked by our team prior to production and before shipment
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Choose Product(s)

  • Select product to print on
  • Select colors, sizes
  • Select print types, locations
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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
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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:

  1. 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.
  2. 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.
  3. 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.
  4. 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.
  5. 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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A 100 piece minimum is needed for an account rep to handle your order.

For online orders

Screen Printing: 25 pieces minimum
Embroidery: 3 pieces minimum
Water-based Transfers: 1 piece minimum
Direct-to-Garment: 1 piece minimum
Patches: 25 pieces minimum

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