Leather patches on fitted and flat-bill caps
Battle Born Clothing has made laser-engraved leather patches since 2020 on an OMTech 80-watt CO2 laser. We glue them to the cap with a heat process on a two-platen press, or sew them on request, and we aim to be the top leather patch hat maker in the USA.
Per-cap price
| Quantity | Per cap |
|---|---|
| 12-23 | $8.00 |
| 24-47 | $7.50 |
| 48-71 | $7.00 |
| 72-95 | $6.50 |
| 96-119 | $6.00 |
| 120-143 | $5.50 |
| 144+ | $5.00 |
Sewn-on instead of glued: add $1.00 per cap. The stitch border is visible and some buyers prefer the look.
Which caps take a patch
- Best: Flexfit 180 Delta (seamless front, patches up to the full panel)
- Good: Flexfit 6277, 5001, 6210, 110F, Richardson 511, 110, 112, YP 6089M, Zapped Cobra: keep glued patches under about 2.5 in wide across the seam, or choose sewn
- Not recommended: thin performance shells such as the 6297F and 6100NU
Shapes, sizes and leather colors
Rectangles, rounded rectangles, circles, ovals, shields and custom outlines cut from your vector file. Typical sizes are 2 in to 3 in wide. Standard leather colors are shown on the proof; engraving burns the design darker into the hide, so high-contrast line art works best.
Artwork
Vector art (AI, EPS, PDF, SVG) engraves cleanest. Fine lines under about 0.5 pt and solid fills larger than about 1 in square are the two things we will flag on the proof. There is no digitizing fee for patches.
Questions
Glued or sewn?
Glued is standard and holds through normal wear. Sewn adds $1.00 per cap and a visible stitch border, and is the better choice for very large patches or thin shells.
Can I combine a patch with embroidery?
Yes. A front patch with a side-hit or back embroidery is common. The embroidery placement is quoted per job plus digitizing.
Is there a minimum for patch caps?
No hard minimum. The 12-23 tier is $8.00 per cap for the patch plus the blank.