Keegan G.
Custom Patch Hats
Custom patch hats put your logo on a woven, embroidered, leather or PVC patch, sewn onto the hat you choose. We’ve been making them for businesses, teams and brands since 2009.
24 hat minimumFree mockupWoven · Embroidered · Leather · PVC4–5 weeks
Trusted by 1150+ Brands Globally
Choose from the Most Popular Patch Hat Styles
Popular Styles
Almost any hat with a front panel can carry a patch. These are the styles our customers order most for patch hats.
Custom Patch Trucker Hats
The classic patch hat on our everyday Otto 39-165 foam front trucker. Mesh back and a firm front panel that holds a patch flat. Pricing below includes the hat, your patch, sewing and a free mockup.
- 5 Panel Hi Profile
- Snapback
- Foam Front
- Slim Rope
- 139 colors available
| Customization | 24 Hats | 50 Hats | 100 Hats | 200 Hats |
|---|---|---|---|---|
| Woven / Embroidered Patch (4–5 weeks) | $20.70 | $16.95 | $14.70 | $12.95 |
| Faux Leather Patch (4–5 weeks) | $21.70 | $17.95 | $15.70 | $13.95 |
| 2D PVC Patch (4–5 weeks) | $22.70 | $18.95 | $16.70 | $14.70 |
*Pricing includes decoration in one location and a free design mockup
*Patch prices are for a patch up to about 3.5 x 2.5 inches
*Over 200 hats? Please email for a custom quote
*Need them sooner? Tell us your in-hands date on your quote and we’ll tell you if we can hit it
*Prices are an example and are subject to change
Patch Dad Hats
Soft and low-profile. A small woven or leather patch looks clean on a washed cotton dad hat.
Patch Snapback Hats
Tall, structured front with a flat bill. Room for a wider patch or a bold PVC logo.
Patch 5-Panel Hats
One seamless front panel, so the patch sits flat with no seam running through it.
Custom Patch Beanies
A patch on the cuff is the cleanest way to put a detailed logo on a knit hat.
Looking for something unique? Our team can source any style or brand to match your exact vision.
Choose Your Patch
Patch Options
Every patch we put on a hat is made to your artwork, then sewn on. Here's how the four main types compare. We also make chenille and sublimated (full-color printed) patches; ask on your quote.
Woven Patch Hats
The thinnest, flattest patch, with the sharpest detail. Woven patches handle small lettering and thin lines better than any other type, so they’re the right pick for detailed logos. Woven patch hats cost the same as embroidered patch hats. See custom woven patches.
Embroidered Patch Hats
Thicker thread, a raised texture and a stitched border around the edge. Embroidered patch hats suit bold logos with a few colors and look great on truckers and snapbacks. See custom embroidered patches.
Leather Patch Hats
Your logo debossed, embossed or laser engraved into genuine or faux leather. Leather patch hats have a rugged, premium look that works on truckers, dad hats and camo. A faux leather patch adds $1 a hat over woven. Genuine leather is priced on your quote. See custom leather patches.
PVC (Rubber) Patch Hats
Soft, flexible rubber with raised, molded detail and solid colors. PVC is waterproof, which makes it a favorite for outdoor brands, fishing and surf. See custom PVC patches.
Patch Size, Shape and Placement
Front patches on a hat usually run 2 to 3 inches. Low-profile hats like dad hats take a slightly smaller patch than a structured trucker or snapback. Not sure? We’ll size it on your free mockup.
Shapes. Rectangles, circles, ovals, shields, hexagons, or a custom shape cut to the outline of your logo.
Edges. A merrow border (the thick, rolled stitch around the edge) gives a classic badge look. A laser-cut edge follows your logo’s outline for a cleaner, modern look.
Placement. The front panel is where most patches go. Want a side or back logo too? Ask on your quote and we’ll price it.
Custom Trucker Hats With Patches
A trucker is the most ordered patch hat we make. The firm front holds the patch flat and the mesh back keeps it cool. Foam front truckers give you a smooth, retro look, and twill front truckers like the Richardson 112 look more finished. Most trucker hats with patches get a 2 to 3 inch patch centered on the front panel. Prices start at $20.70 a hat at 24 and drop to $12.95 at 200. For printing, embroidery and every trucker style we carry, see custom trucker hats.
Custom Patch Hats We Created
Patch Hat Gallery
Real patch hats we've made for our customers: woven, embroidered, leather and PVC patches on truckers, dad hats, snapbacks and beanies.
How Patch Hats Are Made
How It Works
Your patch is made first, and you see it twice before the full order is sewn: a photo of the patch, then a photo of your first finished hat.
01.
Send Your Logo
Pick your hat and send your logo on the quote form.
02.
Free Mockup & Quote
We show the patch on your hat and send pricing.
03.
Approve & Pay
Production starts once you approve and pay.
04.
Approve Your Patch
A photo of your patch before any hats are made.
05.
Approve Your First Hat
A photo of the first finished hat. Nothing else is made until you say yes.
06.
We Finish & Ship
4 to 5 weeks from approval. Need them sooner? Ask.
Decoration Methods for Your Custom Hat
Decorations
Explore our range of decoration methods, including custom patches, embroidery, and printing options designed to suit every style and application.
Custom Patches
From classic embroidered patches to modern PVC and leather, we offer options that bring your brand to life with precision and style.
View Patch Options
Custom Embroidery
From clean logo stitching to detailed threadwork, we deliver finishes that elevate your brand with precision and durability.
View Embroidery Options
Custom Printing
From bold graphics to detailed prints, we deliver results that bring your brand to life with clarity and consistency.
View Printing Options
Premium Hat Brands We Source
We partner with leading hat manufacturers to ensure every custom order feels retail-ready. Whether you prefer the timeless shape of a Richardson 112, the streetwear edge of New Era, or the reliable quality of Yupoong, we’ve got your favorite brands covered.
Richardson
Home of the legendary Richardson 112 — one of the best-selling silhouettes in custom headwear. Rugged, consistent, and a go-to for teams, trades, and outdoor brands.
New Era
The choice of pro sports teams and streetwear brands worldwide. When you want the iconic fitted look, New Era sets the standard.
Flexfit
A top pick for branded merchandise, athletic teams, and lifestyle labels. Their signature stretch-fit band delivers a clean, comfortable fit across every size.
Yupoong
Yupoong's YP Classics line pairs retail-level craftsmanship with workhorse consistency — home to some of the most-ordered blank caps in the industry.
Decky
Affordable, reliable, and versatile. Decky offers one of the largest blank hat selections for bulk orders, giveaways, retail shops, and fast-turnaround merchandising projects.
Otto Caps
A longtime industry staple, Otto produces consistent, high-quality blanks in every style — from foam truckers to structured snapbacks — ideal for embroidery and woven labels.
Fahrenheit
Rugged, outdoor-inspired headwear, Fahrenheit hats handle detailed embroidery and leather patches well. Ideal for custom-branded tactical, outdoor, and lifestyle gear.
AS Colour
Modern, minimalist, and retail-ready. AS Colour hats offer premium structure and a clean profile — perfect for lifestyle brands, fashion labels, and premium merch collections.
Outdoor Cap
A leading name in performance and outdoor-ready hats. Known for crisp lines and durable construction, Outdoor Cap styles are perfect for bold embroidery or PVC patches.
Legacy
Retro-inspired 5-panel and unstructured silhouettes with a lived-in, surf-and-skate vibe. Legacy hats appeal to lifestyle brands looking for a relaxed fit with classic rope and vintage accents.
Imperial
Lightweight, premium, and built for comfort. Imperial hats offer a soft crown and easy fit right out of the box — great for subtle logo embroidery and high-end merch lines.
47 Brand
Officially licensed-quality construction with a sport-heritage feel — a favorite for fan gear, breweries, and lifestyle merch.
Ready to Create Something Custom?
Tell us about your next project — whether it’s custom hats, patches, or branded merch, we’ll help you bring it to life with expert design and production.
Get in TouchFrequently Asked Questions
Everything you need to know about ordering custom patch hats.
Are the patches sewn on or ironed on?
Sewn on, every time. An iron-on or stick-on patch can peel off a curved hat once it gets warm or sweaty. We stitch around the edge of the patch so it stays put for the life of the hat.
Do patch hats cost more than embroidered hats?
Usually not. On the Otto foam trucker, a woven patch and embroidery are both $20.70 at 24 hats. At 200 hats the patch costs less: $12.95 against $14.70. A leather patch adds about $1 a hat and a PVC patch about $2. The trade-off is time: embroidery takes 2 to 3 weeks, patch hats 4 to 5.
Why do patch hats take longer than embroidered hats?
Because your patch is made first. Once you approve your proof, we make your patches, send you a photo of the sample, then sew the first hat and send you a photo of that too. The full run starts only after both approvals.
Can I see my patch before the whole order is made?
Yes. You approve a photo of your patch before any hats are made, then a photo of the first finished hat before the rest are sewn. If something isn’t right, we fix it before the full order goes ahead.
What size should the patch on my hat be?
Most front patches run 2 to 3 inches. Truckers, snapbacks and 5-panel hats take the larger end. Dad hats have a lower crown, so a slightly smaller patch fits better. We’ll size the patch on your free mockup so you can see it on the hat before you decide.
Where does the patch go on a trucker hat?
Centered on the front panel, just above the bill. It never touches the mesh, so the back of the hat stays cool and flexible. If your logo is tall, we’ll lift it a little so it doesn’t crowd the bill.
Which hats work best with a patch?
Any hat with a firm front panel. Structured truckers and snapbacks give a patch a flat, steady surface, and the Richardson 168’s seven-panel front is made for big patch designs. On a soft dad hat a smaller patch sits best, and on a beanie the patch goes on the cuff.
Built on Trust, Quality, and Speed
Why Choose Consolidated Ink
We deliver retail-quality custom products with precise embroidery, structured fits, and reliable production.
Low Minimum Orders
Order as low as 24 hats per design. Perfect for small teams or test runs.
Free Design Support
Send a logo or idea, we refine, digitize, and mock it up at no cost.
Fast Turnaround
Most orders are shipped within 2–3 weeks, with rush options available.
Discounts on Bulk Orders
Tiered discounts that make larger orders more cost-effective.
Retail-Grade Quality
Premium brands, finished with high-quality embroidery, patches, and prints.
Satisfaction Guaranteed
If something’s off, we fix it.
Simple as that.
5.0 Star Reviews on Google
Hear first-hand from our incredible community of customers.
I have had countless orders with Consolidated over the last 10+ years. Hats, hoodies, shirts, embroidery... the attention to detail is something I never have to question, and my recent order of 144 t-shirts was no different. I didnt even need to check the print before I put the order in the back of the truck. Thank you guys.
Consolidated Ink was such a pleasure to work with! Professional, punctual and extremely communicative. Not only was all the design and printing Perfect, but the materials they recommended were great quality. I have already placed a full re-order with them. Highly recommend using Consolidated Ink.
Could not be happier. Needed a small quantity of T-shirts for an important public event -- and fast! Not only was the whole job turned around on a dime, but the result was terrific -- and they actually improved the main graphic, generating a higher resolution version. Never going anywhere else.
We used consolidated ink to curate our swag for the local little league… our merch is the talk of the town and sought out by many! Coolest hats and softest t-shirts around. We even had a tight deadline and they came through for us!
The team at Consolidated Ink did such a great job. They turned around merchandise for us in such a fast manner - even got great delivery and complete quality were so thrilled with results thank you thank you
Would highly recommend anyone work w Consolidated Ink - incredibly detailed, professional & reasonably priced. Pat was able to source exactly what I needed and got the job done within days of placing the order. 5 stars!