How to choose the right customization for your gear
Ready to bring your logo to life? Explore our ultimate guide to custom patch types and direct embroidery to find the perfect match for your team’s gear.
Written By: Amy
June 12, 2026
You’ve got an awesome logo ready to go. You’ve picked out the perfect gear. And now, it’s time for the big question: which customization method will actually do your brand justice?
From classic fabric patches and direct embroidery to dimensional PVC rubber, sleek TPU, and timeless leather, every customization style comes with its own unique strengths (and sometimes a few technical limitations). Don’t worry—you don’t have to figure it out alone. Our local design team handles the heavy lifting, but we want to give you a backstage pass to how these options work.
Below, we’ll break down our core customization options, what they do best, and even let you in on some insider industry lingo so you can talk the talk. Once you’ve spotted your perfect match, you can head over to our quote form, connect with a designer, and get your project rolling!
The Classic: Custom Fabric Patches
Generally speaking, there are three main types of fabric patches. There are three main types of fabric patches: Embroidered, Woven, and Sublimated. The type of fabric patch our team recommends depends on your artwork.
Before we dive into the differences, you’ll probably hear us use the term merrowed edge. A merrow is just that raised, embroidered border around the embroidered, woven, and sublimated patches. It gives it a clean, finished look while also securing the patch’s interior threads and providing a perfect guide for our stitch team to attach the patches securely to your hats.
When should you choose custom embroidered patches?
Embroidered patches use a thick thread to build up your image. You’ve definitely seen this look before on classic mechanic work shirts and retro souvenirs. Because the thread is thick, the overall patch gets a nice dimensional, 3D effect. The only drawback of those thick threads is that they make it a bit harder to capture thin lines, fine details, and tiny text. For patches with details you want to get just right, we know another style that might be a better fit…
1010 Performance Hat and Yupoong Trucker hat with custom embroidered patches
Each embroidered patch is hand-stitched to the hats by our team in Raleigh, North Carolina.
What is the difference between woven and embroidered patches?
By contrast, woven patches use a much thinner thread, which allows us to capture your artwork’s details crisp and clear. Because the threads are so thin and tightly woven, we can handle much finer lines without losing clarity. We also have more thread colors available for woven patches, so there is greater opportunity to match your exact brand colors or select a color that pairs perfectly with a specific hat or hoodie in your order.
A woven patch in the shape of our home state, North Carolina.
Richardson 112 trucker hats with custom woven patches.
What designs work well for custom sublimated patches?
While woven patches can capture a good amount of detail, we are limited to 10 colors, and highly complex logos with gradients or color blending often require simplification. If you have a high level of detail that just can’t be changed, we can digitally print your artwork directly onto a fabric backing to create a sublimated patch. Sublimated patches work best for things like photographs, paintings, and complex illustrations.
That said, when simplification is possible, we always recommend going with a woven patch instead. The woven thread colors will naturally look more vivid and bold, which always packs more of a punch at a small patch size.
Outdoor Cap trucker with a sublimated patch and a straw lifeguard hat with a sublimated patch with embroidery added over the top.
Sublimated patches like this example are printed to capture all the details and colors of your design.
The Heat-Press Option: Die-Cut Embroidered Patches
Alternatively, if your logo needs a unique contour, full embroidery is the only fabric patch that works for custom die-cut shapes. Since they don’t have a merrowed edge, they are heat-cut to match your design.
The catch? Our sewing machines can’t follow those complex shapes, so these have to be heat-pressed onto the hats instead of hand-stitched. We always prefer the premium look and durability of a stitched patch, but if your design absolutely needs a complex, custom shape, we can make it happen.
Richardson 168 7-panel and Richardson 112 6-panel trucker with custom die-cut embroidered patches.
The Natural Look: Custom Leather Patches
Genuine leather patches offer a high-end, premium look that works best with single-color designs. Instead of printing with ink, your design is physically stamped or burned into the leather, usually resulting in a shade just a bit darker than the natural leather color. We offer two processes for our genuine leather patches, and there are specific reasons to choose one over the other.
When do custom-stamped leather patches work best?
Stamped leather is a great choice because it generally allows for finer details and offers a wider variety of leather colors to choose from—including classic browns, tans, greys, blues, whites, and more.
If you want additional color added to your logo beyond the natural shade of the stamped leather, we can add a color deboss to your design. This upgrade allows you to add up to six colors to your patch, including metallic gold and silver, for a really unique look.
When do custom laser-engraved leather patches work best?
On the other hand, laser-engraved leather patches have your design burned directly into the material using a precision laser. These come in four main colors: Natural, Mocha, London Tan (our most popular option), and Black.
While laser engraving doesn’t capture tiny details quite as finely as stamped leather, we make these patches completely in-house. This allows for a much faster turnaround time, making laser-engraved leather the perfect option if you are on a tight deadline or in a rush.
Legacy MPS Trucker and Yupoong 6245 dad hat with custom laser-engraved leather patches.
Laser-engraved leather patches have your design engraved into the leather for a rustic natural look.
What if I want to wash my gear with leather patches?
Stamped leather holds up to washing really well. For a rush option, we can create performance leatherette patches, a fantastic, water-resistant alternative to our laser-engraved genuine leather patches. Because this is a hybrid material crafted with real leather fibers, it still gives you that authentic look and feel while holding up much better on gear that needs frequent washing. We offer all the classic leather colors in this material, but you can always ask your designer about our metallic and additional color options, too.
Clean + Modern: Custom PVC Patches
PVC patches are made from layers of colored rubber, giving your design a clean, dimensional 3D look. They’re super durable and flexible, and they work best with bold, simple artwork. To make these, custom molds are created that create your logo using different raised levels on a solid background.
Beyond the unique 3D look, another important detail here is how they’re attached. Every PVC patch we make includes a built-in stitch channel, allowing our team to hand-stitch it securely to your gear. A lot of competitors just use glue for these thick patches, which doesn’t last and will eventually cause the patches to peel and fall off. We hand-stitch them so they’re built for the long haul.
Richardson 112 trucker and Burnside flannel with matching PVC patches.
Close-up of a 3D PVC patch hand-stitched onto a crew favorite flannel.
The Traditional: Custom Direct Embroidery
Moving away from custom patches, we also offer classic direct embroidery with your artwork stitched straight into your gear. This can be a subtle add-on—like text above the snapback of a hat—or the absolute star of the show, like your logo on the chest of a polo shirt or fleece vest.
The main thing to keep in mind is that direct embroidery requires relatively simple artwork. Because the needles pierce the fabric of the hat or shirt, highly intricate details, tiny text, or complex shading just don’t translate well. If your design has a lot going on, the design won’t be readable, and the fabric can start to bunch up or look messy, for those hyper-detailed logos, a woven or sublimated patch is always your best bet to keep things looking sharp.
Otto Cap 31-069 Two Tone Baseball (no mesh hat) and the Richardson R256 rope hat with direct embroidery. Add your brand!
A New Spin: Custom 3D Puff Embroidery
If you want to take this classic style and give it a modern look, you can upgrade to 3D Puff Embroidery. For this process, we place a specialized foam insert beneath the stitches to lift the thread off the hat. This creates a bold, chunky look that you see all the time on professional baseball caps and streetwear brands. It’s perfect for big, blocky letters or thick, simple icons that you really want to pop. Partial puff embroidery is also an option, using a base layer of flat embroidery with puff embroidery layered right on top.
Richardson 112LN in Ice Grey with a woven clip label and in black with an offset woven patch
For the perfect finishing touch, we love this custom R112LN hat in Autumn Brown/Black with a leather patch. And don’t forget a winter ready hoodie!
Off the Chain: Custom Chain Stitch Embroidery
Looking to add a bit of unique texture to your direct embroidery? Chain stitch is a classic technique that creates a textured, rope-like effect that looks incredible for text and clean line details. We’re loving this look lately, and we recently introduced 3D Chain Stitch Embroidery. This style combines that textured, rope-like look of a chain stitch with a foam base (just like Puff Embroidery) to create a high-relief, 3D effect that really stands out.
Richardson 112 truckers with 3D Chain Stitching designs.
Close-up of 3D Chain Stitching.
Sleek & Borderless: Custom TPU Applique
For a completely different, high-tech style, TPU (Thermoplastic Polyurethane) is a thin, sleek rubber-plastic hybrid that is heat-pressed directly onto the hat or gear. Because it’s applied straight to the fabric, you don’t need a heavy background or border like a traditional patch. Your design just sits seamlessly on the gear.
Typically, these appliques have a smooth, glossy finish that really catches the light, but matte or textured options are also possible. TPU can capture much smaller details than direct embroidery and can even be digitally printed for more complex artwork, making it a huge favorite for performance apparel and golf hats.
Richardson 355 Performance Hat and remote crew favorite joggers with TPU applique.
The Perfect Accent: Custom Woven Clip Labels
Finally, woven clip labels are designed to wrap completely around the edge of your gear. You’ll usually see them folded over the bottom rim of a hat or above the snapback, the hem of a sweatshirt, the bottom of an uncuffed beanie, or the top fold of a cuffed beanie.
They pair beautifully with a primary front patch to sneak in some additional information on your gear. Some of the most popular ways we see clients use them are to celebrate big milestones (like a 25th company anniversary), to add a small American flag, or to display a secondary brand icon. That said, they can also be used completely on their own if you are going for a more subtle, minimalist look! For those looking for a different texture, our suede options are a highly popular choice for beanies.
The cherry on top! Add a woven or suede clip label to hats, beanies, and gear.
The CPH Customization Cheat Sheet
| Customization Type | The Vibe | Best For |
|---|---|---|
| Embroidered Patches | Textured, classic, and retro with a slight 3D feel. | Bold logos with clean lines and simple text. |
| Woven Patches | Smooth, crisp, and capable of handling detailed artwork. | Intricate logos, fine lines, and precise brand colors. |
| Sublimated Patches | High-definition digital printing with infinite color blending. | Photos, landscapes, illustrations, and complex gradients. |
| Die-Cut Embroidered Patches | Borderless, custom-shaped fabric patches (heat-pressed, not stitched). | Unique silhouette, bold logos that don’t fit a standard stitchable shape. |
| PVC Patches | Durable, multi-level 3D patch. | Bold and simple designs and logos. |
| Stamped Leather | High-end leather look with your design pressed in to create a recessed look. | Capable of capturing fine details and adding color deboss. |
| Laser-Engraved Leather | Classic, rustic, burned look. | Timeless style and fast turnaround times for tight deadlines. |
| Performance Leatherette | Authentic leather look and feel, but water-resistant. | Active gear, workwear, or hats that need frequent cleaning. |
| Direct Embroidery | Stitched straight into the fabric for a seamless retail finish. | Bold, minimal logos and simple text add-ons. |
| 3D Puff Embroidery | Chunky direct embroidery raised off the hat. | Big, blocky lettering and simple icons/logos. |
| TPU Applique | Sleek and modern, rubber-plastic hybrid. Heat-pressed onto hats. | Performance apparel, athletic gear, and golf hats. |
| Flat Woven Labels | Thin woven patch without a border. | Matching gear bundles with hats, apparel, and bags. |
| Woven Clip Labels | Edge-wrapping accent that clips around hems and folds. | Milestone anniversaries, flags, or subtle secondary logos. |
Wrapping It Up: Let’s Build Your Gear
At the end of the day, you don’t need to be a decoration expert to get incredible gear, and that’s exactly what we’re here for. Whether you know exactly which patch type you want or you’re still sitting there looking at your logo, wondering which path to take, our team has your back.
When you work with Custom Patch Hats, you get paired with a real, talented designer who will review your unique artwork and recommend the best way to make your brand shine. From the first mockup to the final stitch, we ensure the process is seamless and the quality is unmatched.
