Affixing Custom Patches To Hats
Many operate under the assumption that the only type of patch that can be affixed to a custom cap
or hat is the embroidered type. Additionally, some also believe they are limited to a stock
patch size or even a single placement on a hat. Thankfully, both of these assumptions are false.
Here, we will inform you of the options available to you. Consider how one of our customers,
Anthony Milavic of The Butter Cutter, utilized many of our cap customization options.
Customization #1 - Different Types of Patches
The patches you affix to your custom caps don't have to be embroidered; you can also affix woven
patches, printed patches, and even woven labels. Most people opt for the woven or printed option
when their design contains a lot of small detail that would be limited by the embroidery
process. Shown here is the woven patch that Anthony of The Butter Cutter affixed to the front
of his caps.
Customization #2- Different Types of Hats
True, the most popular type of headgear that incorporates custom patches is the cap; however,
patches can also be affixed to beanies, head-bands, visors, canvas sun hats, and more.
Basically, custom patches can be attached to any type of headgear that is made of fabric. Iron
on backing is appropriate for natural materials that are thick, while sewing is the better
choice for synthetic and thin materials. This is not to say that one absolutely cannot attach a
custom patch to headgear such as a helmet—likely, a solution such as heavy-duty super glue would
work, but we at Stadri cannot claim to have knowledge of any specific instance where someone has
Customization #3 - Different Placement Locations
The most standard placement is front and center. Many other patch placements are available,
though. You can see from the image on the right that Anthony opted for two different placements:
one in the standard spot and one that curves along the bill. Other placements available are the
back, the side of the hat, and the side of the bill.
Customization #4 - Different Patch Sizes, Borders, Backings, etc
If you want to sew your patch, order it with plastic backing or without backing. Plastic backing
adds more thickness and stiffness to the patch, whereas not having a backing at all makes the
patch more thin and flexible-it's up to your personal needs and preferences. As far as borders
go, you have the option of either merrowed (wrap around) or diecut (cut to shape). We recommend
a diecut border for hats for two reasons. First, if your patch is cut to shape, it gives the
appearance of being directly embroidered right into the cap, making the cap and patch seem more
integrated. Second, diecut patches tend to stay affixed as securely as the day you got them, for
the life of the hat.
If you're placing your patch on the front, standard location, the overall patch size is limited
to 3", but if you're placing the patch in a less traditional location, more size options will
opened up to you. Note how the scrambled eggs patch that Anthony placed on the bill of the cap
was able to be nearly 6" wide.
Many other customizations exist, most involving the custom caps themselves, such as different
fabrics, bill styles, and enclosures. Give us a call at 1-800-679-7909 to learn more.