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Custom Hats: Patch Guide

Compare Patches — Intro

Compare Patches

Compare the type of patch to find the one that best suits your needs. Each type offers different characteristics — from classic embroidered patches with a textured, traditional look to modern PVC or woven patches that provide greater detail and durability.

By reviewing the available options, you can choose the style, finish, and material that perfectly match your design, application, and intended use.

This comparison helps ensure your final patch not only looks great but also performs well in the conditions you need it for.

Comparison of patch hat types
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Compare Patches — Section
Woven patch
Woven Patch
PVC patch
PVC Patch
Embroidered patch
Embroidered Patch
Leather patch
Leather Patch
Printed patch
Printed Patch
Sublimated patch
Sublimated Patch
Logo Detail
Best!
Cost (low→high)
Best!
Production Speed
Best!
Weather Resistance
Best!
Flexibility
Best!
Woven Patches — Section
Woven patch close-up

Woven Patches

Our high-quality woven patches will give your cap a clean and highly detailed look. This decoration method delivers crisp lines and excellent definition in even the smallest elements. Ideal for multi-colored logos with fine or intricate detail. The texture of the patch is smooth and tightly stitched for durability. Your design can include gradients and precise lettering.

Woven patch hat
Woven patch hat
Woven patch hat

Woven Patches Perks

Logo Detail
Cost (low→high)
Production Speed
Weather Resistance
Flexibility
Best!
Best!
Best!
CJ Ayers

Want to see your logo?

CJ Ayers

Account Executive,
is here to help you.

Preview Your Logo

Why Choose
Woven Patch Hats?

High Detail and Clarity:

Delivers crisp lines and sharp definition, perfect for intricate designs.

Smooth Texture:

Features a clean, tightly woven surface that feels smooth and refined.

Cost Effective for Complex Artwork:

Offers a budget-friendly option for detailed, multi-colored designs without losing quality.

Woven patch example Woven patch example

PVC Patches — Section
PVC patch close-up

PVC Patches

Our high quality PVC patches will give your cap a very bold and technical look. This decoration method adds an amazing level of dimension to any design. Ideal for multi-colored logos with a moderate level of detail. The texture of the patch is like rubber but with a lot more stability. Your design can be 2D or 3D.

PVC patch hat
PVC patch hat
PVC patch hat

PVC Patches Perks

Logo Detail
Cost (low→high)
Production Speed
Weather Resistance
Flexibility
Best!
CJ Ayers

Want to see your logo?

CJ Ayers

Account Executive,
is here to help you.

Preview Your Logo

Why Choose
PVC Patch Hats?

Bold & Dimensional:

Raised, 3D design for a striking, professional look.

Weather-Resistant & Durable:

Perfect for outdoor wear, work uniforms, and active lifestyles.

Versatile & Customizable:

Available in multiple shapes, sizes, and color options.

PVC patch example PVC patch example
Embroidered Patches — Section
Embroidered patch close-up

Embroidered Patches

Our high-quality embroidered patches will give your cap a classic and textured look. This decoration method adds rich depth and dimension with raised stitching. Ideal for bold logos, strong shapes, and designs that benefit from a handcrafted feel. The surface of the patch has a traditional thread texture that adds character and durability. Your design can feature vibrant colors and distinct embroidered details.

Embroidered patch hat
Embroidered patch hat
Embroidered patch hat

Embroidered Patches Perks

Logo Detail
Cost (low→high)
Production Speed
Weather Resistance
Flexibility
Best!
CJ Ayers

Want to see your logo?

CJ Ayers

Account Executive,
is here to help you.

Preview Your Logo

Why Choose
Embroidered Patch Hats?

Classic Textured Look:

Provides a traditional embroidered finish with rich, raised stitching for a timeless feel.

Durable:

Built with tightly stitched threads that hold up well to regular wear and long-term use.

Versatile and Popular:

Works well for a wide range of designs and remains a favorite choice for its classic appeal.

Embroidered patch example Embroidered patch example
Leather Patches — Section
Leather patch close-up

Leather Patches

Our high-quality leather patches will give your cap or garment a premium and sophisticated look. This decoration method adds a rich, natural texture that enhances any design with an elegant touch. Ideal for logos, monograms, or minimalist designs that benefit from a luxurious feel. The surface of the patch is smooth yet durable, with a distinctive leather grain that improves over time. Your design can be embossed, debossed, or printed for a refined and timeless finish.

Leather patch hat
Leather patch hat
Leather patch hat

Leather Patches Perks

Logo Detail
Cost (low→high)
Production Speed
Weather Resistance
Flexibility
CJ Ayers

Want to see your logo?

CJ Ayers

Account Executive,
is here to help you.

Preview Your Logo

Why Choose
Leather Patch Hats?

Premium Rugged Look:

Delivers a high-end, natural leather texture that feels both sturdy and sophisticated.

Long Lasting Durability:

Made from quality leather that withstands wear and maintains its appearance over time.

Natural Finish:

Showcases the authentic texture and grain of real leather for an elegant, organic look.

Leather patch example Leather patch example
Printed Patches — Section
Printed patch close-up

Printed Patches

Our high-quality printed patches will give your cap or garment a crisp and colorful look. This decoration method allows for sharp, detailed designs with vibrant colors and precise lines. Ideal for multi-colored logos, intricate patterns, or artwork that requires exact replication. The surface of the patch is smooth and lightweight, providing a clean finish. Your design can include unlimited colors, fine text, and complex graphics, making it perfect for eye-catching customization.

Printed patch hat
Printed patch hat
Printed patch hat

Printed Patches Perks

Logo Detail
Cost (low→high)
Production Speed
Weather Resistance
Flexibility
CJ Ayers

Want to see your logo?

CJ Ayers

Account Executive,
is here to help you.

Preview Your Logo

Why Choose
Printed Patch Hats?

Great for Rush Orders:

Fast production, delivered quickly while maintaining high quality.

High Level of Detail:

Captures intricate designs and fine lines with precision and clarity.

5 Shapes and 13 Colors:

Offers a variety of shapes and a vibrant palette for versatile designs.

Printed patch example Printed patch example
Sublimated Patches — Section
Sublimated patch close-up

Sublimated Patches

Our high-quality sublimated patches will give your cap a vibrant and seamless look. This decoration method allows for full-color designs with intricate patterns, gradients, and photographic detail. Ideal for complex logos or artwork that requires precise color reproduction. The surface of the patch is smooth and lightweight, making it flexible and comfortable to wear. Your design can include unlimited colors without any stitching limitations, resulting in a sharp and eye-catching finish.

Sublimated patch hat
Sublimated patch hat
Sublimated patch hat

Sublimated Patches Perks

Logo Detail
Cost (low→high)
Production Speed
Weather Resistance
Flexibility
CJ Ayers

Want to see your logo?

CJ Ayers

Account Executive,
is here to help you.

Preview Your Logo

Why Choose
Sublimated Patch Hats?

Full Color Printing:

Reproduces intricate designs and gradients with vibrant, true-to-life colors.

Lightweight and Flexible:

Thin and soft, easily conforming to the shape of any garment or accessory.

Can Replicate Color Gradients:

Perfect for designs with smooth transitions and detailed, multi-color artwork.

Sublimated patch example Sublimated patch example
Sizes & Shapes — Section
Custom patch on a cap — sizes and shapes

Sizes & Shapes

We can create any patch shape desired! The most common is to use simple shapes — square, rectangle, oval, circle, etc — these work best for a merrowed edge border (which is what most people want) — and we can size the shape however is needed to best fit the logo. We use rectangles a lot, but often it's dictated by the shape/layout of the customer's logo and what will make it look best. Often, customers have some specific ideas as well and we can almost always accommodate.

We can create detailed patch shapes as well — usually on these we have to do an embroidered edge as too much detail in shape won't work for merrowed edge.

Send us your logo completely free of charge and see how it will look on a mockup prepared by us. We usually reply within 24 hours!

Preview Your Logo
Circle patch shape
Circle 2.5" x 2.5"
Oval patch shape
Oval 3.5" x 2.5"
Rectangle patch shape
Rectangle 3.5" x 2.5"
Hexagon patch shape
Hexagon 3.5" x 2.5"
Square patch shape
Square 2.5" x 2.5"
Diamond patch shape
Diamond 2.5" x 2.5"
Rectangle patch shape
Rectangle 3.5" x 2.2"