Custom Patches for Hats
cap-front sizing · leather, PVC, embroidered or woven · finished-hat option from 50
The hat decides the patch. A trucker cap's foam front takes any patch style; a structured richardson-style crown wants something stiff like leather or PVC; an unstructured dad hat pairs with a soft embroidered piece that follows the curve.
This page is the routing station: sizes and materials that fit cap fronts, plus the finished-hat option where we source blanks and ship ready-to-sell hats.
Sizes that fit a crown
Cap fronts want width, not height: 2.5 to 3 inches wide by 1.5 to 2 inches tall covers nearly every style. Anything taller collides with the seam line. We keep cap-standard dies for rectangles, ovals, and shields ready to run.
Patches only, or finished hats
Most orders take patches only and hand them to a hat vendor. From 50 pieces we can do the whole job: source the blanks in your colorway, apply the patches, and ship retail-ready hats in one box with one invoice.
Pricing
| QUANTITY | PRICE PER UNIT | ORDER TOTAL |
|---|---|---|
| 25 | $3.90 | $97.50 |
| 100 | $2.10 | $210.00 |
| 300 | $1.60 | $480.00 |
| 500 | $1.30 | $650.00 |
Patch-only orders use the standard patch tiers; finished hats are quoted per blank style.
Common questions
Leather for the premium boutique look, PVC for outdoor and workwear brands, embroidered for classic team caps, woven when the logo has fine detail. If you send the hat style you are using, we recommend with the proof.
On flat-front foam truckers, heat-seal works. On structured or curved crowns, stitching is the only attachment that lasts, which is why the finished-hat option exists.
Blank plus patch plus application typically lands between $9 and $14 per finished hat at 100 pieces, depending on the blank you pick. That leaves room under a $30 retail price.