To put a patch on a hat, center it on the front panel about 1/2 to 3/4 inch above the brim, then either sew it on with a curved needle and thread that matches the border, or iron it on if the cap is cotton or twill with no foam or mesh. Use a 2 to 2.5 inch patch for a cap front.
Hats are curved and stiff, which makes them harder than a flat jacket. This guide covers placement, sewing, ironing, glue and Velcro, and which method suits which hat.
Need patches for your hats?
Custom hat patches in embroidered, woven, PVC or sublimated, sized for cap fronts, from 25 pieces. Free mockup within 6 hours and a physical sample first.
Which method for which hat
| Hat | Best method |
|---|---|
| Cotton or twill dad cap | Sew or iron on |
| Structured baseball cap | Sew (curved needle), or iron on if cotton |
| Foam front trucker hat | Sew or fabric glue. Never iron. |
| Mesh back trucker hat | Sew onto the front panel only |
| Beanie | Sew onto the cuff |
| Tactical cap with loop panel | Velcro hook backing |
Placement
- Cap front: centered on the seam between the two front panels, with the bottom of the patch about 1/2 to 3/4 inch above the brim.
- Side: a smaller patch, about 1.5 to 2 inches, centered on the side panel.
- Beanie: centered on the folded cuff, sewn through one layer only so the cuff still folds.
Mark the spot with chalk or a pin and look at it in a mirror while wearing the hat before you attach anything.
How to sew a patch on a hat
- Pin or clip the patch in place, or use a dab of fabric glue to hold it.
- Use a curved needle and about 18 inches of polyester thread matching the border. Knot the end.
- Reach inside the hat and push the needle up through the front so the knot sits inside, just under the border.
- Stitch around the edge, going down just outside the patch and up through the border about 1/8 inch along.
- Around the sweatband, lift it up and stitch above it so the band stays comfortable.
- Knot inside and trim. Full steps are in how to sew on a patch.
How to iron a patch on a hat
- Check that the front is cotton or twill, with no foam or mesh.
- Stuff the hat with a rolled towel so the front is firm and curved.
- Set the iron to cotton, steam off. Cover the patch with a thin cloth.
- Press firmly for about 30 seconds, rocking the iron gently to follow the curve.
- Let it cool completely, then check the edges and press again if needed.
A small travel iron or a hair straightener is easier to handle on a curved crown. More detail is in how to iron on a patch.
Fabric glue
A strong fabric glue works on foam trucker fronts and for a quick fix. Spread a thin layer on the back of the patch, press it on, hold it with clips and leave it to set for the time on the bottle, usually 24 hours.
Frequently asked questions
What is the best way to put a patch on a hat?
Sewing by hand with a curved needle is the most secure and works on every hat. Iron-on is quicker but only for cotton or twill caps without foam or mesh.
Can you iron a patch onto a trucker hat?
Not onto the foam or mesh. Foam fronts can melt and mesh does not give the glue enough to grip. Sew it, or use fabric glue on foam.
Where should a patch go on a hat?
Centered on the front panel, with the bottom of the patch about 1/2 to 3/4 inch above the brim. Beanies take the patch centered on the folded cuff.
What size patch fits a hat?
Usually 2 to 2.5 inches for a cap front and up to about 3 inches for a beanie cuff.
Can I use Velcro on a hat?
Yes, if the hat has a loop panel on the front. Then any patch with hook backing can be swapped in and out.
Order custom hat patches
We make embroidered, woven and PVC hat patches from 25 pieces. See custom hat patches or price yours on the quote page. Free mockup within 6 hours and a physical sample before production. Questions? WhatsApp us at +1-437-703-7747.