Custom Embroidered Patches

Embroidered Patches for Hats

Custom embroidered patches are one of the most popular ways to brand hats, caps, and beanies. Unlike direct embroidery — which requires specialized equipment and can distort thinner hat materials — an embroidered patch is produced separately and then sewn or ironed onto the hat. This gives you a clean, consistent look across your entire inventory.

Our hat patches are available with iron-on backing for quick application or sew-on attachment for maximum durability. The most popular sizes for hat patches are 2 to 3 inches, fitting comfortably on the front panel of structured caps. We produce patches with either a classic merrow border (the raised, stitched edge) or a clean laser-cut edge for a more modern look.

Whether you're creating branded merchandise, team caps, or promotional giveaways, custom embroidered hat patches deliver a professional, tactile finish that customers notice.

Embroidered Patches vs Woven Patches: Key Differences

Both embroidered and woven patches are fabric-based, but the production method creates a very different look and feel.

Embroidered patches are made by stitching colored thread onto a twill backing with an embroidery machine. The thread sits on top of the backing, creating a raised, three-dimensional texture you can feel. Embroidered patches have a classic, substantial look that's bold and eye-catching. Best for: larger designs, bold logos, and designs where texture matters.

Woven patches are produced on a loom, with the design woven into the fabric itself. This creates a thinner, smoother patch with much finer detail — small text, intricate lines, and subtle color gradients come out crisp and clear. Best for: detailed logos, small text, and designs where precision matters more than texture.

Quick comparison: • Detail level: Woven wins — can reproduce text as small as 1mm • Texture: Embroidered wins — raised, tactile surface • Thickness: Woven is thinner, sits flatter on garments • Cost: Similar at most quantities • Durability: Both excellent; woven slightly more resistant to snagging