Cap front
The main branding position. Sized by height: 2.25″ for a smaller look, 2.5″ recommended, 2.75″ for a larger presence. Width follows your artwork proportions.
Hats & Caps
Custom Patches for Hats & Caps
Cap patches are a sizing problem before they are a production problem. Get the height right, pick a construction that survives a curved panel, and the rest is straightforward. Orders start at 5 pieces and you approve a free digital mockup before paying.
No setup fees · Tracked Shipping | No Extra Charges
Cap front sizing
Cap-front patches are sized by height, not by a fixed square. You choose the height and we calculate the width from your artwork, so a wide wordmark stays wide and a round crest stays round.
Small
2.25″ high
Subtle, sits well under a low crown
Recommended
2.5″ high
The everyday cap-front fit
Large
2.75″ high
More presence on structured caps
Full guidance lives in the hat patch sizing guide, and you can hold your artwork against a real ruler with the actual size visualizer.
Placement by panel
Left or right side panel
Smaller secondary marks — a monogram, icon or short word. Side panels curve, so simple shapes hold their line better than wide rectangles.
Cap back
Above the closure on a snapback or below it on a curved dad cap. Keep it low and wide rather than tall; the closure eats vertical space.
Structured caps hold a flat patch cleanly across the front panel. Unstructured and curved caps flex, so keep the patch narrower and avoid long straight edges that fight the curve.
Which patch type for a cap
Embroidered
The default cap patch. Stitched texture reads well on structured fronts and holds shape through wear.
Embroidered patchesWoven
Flatter and finer. Choose it when your logo has small lettering or thin lines embroidery would thicken.
Woven patchesPVC
Molded rubber. Weatherproof and rigid, so it suits outdoor and tactical caps more than soft everyday hats.
PVC patchesNot sure? Patch Advisor recommends a construction from your artwork, or read woven vs embroidered patches.
Backing for caps
Sew-on and iron-on / heat seal are included at no extra charge and are what most cap orders use. Hook-and-loop carries a small per-patch surcharge and belongs on gear where the patch is meant to be swapped, not on everyday headwear.
What it costs
Pricing is instant for patches up to 4 inches on the longest side, which covers every standard cap patch. 25 embroidered patches at that size are $120 total. Per-piece cost drops as quantity rises.
Hat patch questions
What size patch fits on a hat front?
2.5 inches high is the recommended cap front size, with 2.25 inches for a smaller look and 2.75 inches for a larger one. Width is calculated from your artwork so nothing is stretched or cropped.
Which backing is best for caps?
Sew-on or iron-on for patches that stay on the cap permanently. Hook-and-loop is for gear where patches need to come off, not for everyday caps, and carries a small per-patch surcharge.
Can I order patches for a small batch of hats?
Every custom patch type starts at 5 pieces: embroidered, woven, printed, chenille, leather, PVC and glow-in-the-dark PVC. Larger quantities simply lower your per-piece price.
How long does a hat patch order take?
Standard turnaround is 10–14 business days after you approve the sample photo. No payment until you approve the mockup.
Do you apply the patches to hats?
We produce the patches and ship them to you with your chosen backing. Application to caps is handled on your side or by your decorator.
Send your logo, see it on a cap size
We come back within 24 hours with a digital mockup, a recommended cap-front height and a firm price. No payment until you approve the mockup.