Laser-engraved leather patches on bucket, dad and 5-panel hats
Battle Born Clothing has cut and engraved leather patches since 2020 on an OMTech 80-watt CO2 laser. Patches are glued with a proprietary heat process on a two-platen VEVOR hat press, or sewn on request. No setup fee, no plates, no minimum. We aim to be the top leather patch hat maker in the USA.
Leather patch price per hat
| Quantity | Glued | Sewn |
|---|---|---|
| 12-23 | $8.00 | $9.00 |
| 24-47 | $7.50 | $8.50 |
| 48-71 | $7.00 | $8.00 |
| 72-95 | $6.50 | $7.50 |
| 96-119 | $6.00 | $7.00 |
| 120-143 | $5.50 | $6.50 |
| 144+ | $5.00 | $6.00 |
Add the blank. Bucket, dad and 5-panel blanks are quoted per job. Reference with a known blank: a Richardson 112 trucker ($13.50) with a glued patch is $21.00 at 24, $20.50 at 48 and $18.50 at 144.
Which hats take a patch best
5-panels: the easy one
YP 6502, Richardson 112FP, 112PFP and Decky 6030 and 6304 all have a single flat front panel. A rectangular patch up to about 3 x 2 inches sits flat with nothing under it. This is why most leather patch hat orders are five-panels or Richardson 112 truckers.
Dad hats
Six-panel dad hats like the YP 6245CM and Decky 205 have a center seam. We size the patch to 2.5 x 1.5 inches or smaller and press it across the seam; it holds. Rounded corners look right on a low crown.
Bucket hats
The Decky 961 and 450 take a glued patch on the front panel. On terry (Decky 980) and ripstop (5301, 5303) we recommend sewn, which adds $1 per hat and is the hold we trust on those fabrics.
Patch options
- Shapes: rectangle, rounded rectangle, circle, oval, shield, or a custom outline cut from your artwork.
- Leather colors: natural tan, brown, dark brown and black are the standards. Engraving burns darker on light leather and lighter on black.
- Sizes: most patches run 2.5 to 3 inches wide. The hat and panel set the limit; the proof shows the patch at true size.
- Glued (standard) or sewn (+$1 per hat).
Artwork for engraving
Send a vector file (AI, EPS, PDF, SVG). Solid shapes and lines engrave cleanly; gradients and photos do not. Line weights under 0.5 pt disappear. Read artwork that engraves and embroiders well before you send.
More on the main site: https://battlebornclothing.com/pages/custom-leather-patch-hats
Questions
Will a glued patch come off a bucket hat?
Not in normal wear. We glue with a heat process on a two-platen hat press, the same process we have used on hats since 2020. For terry and ripstop we recommend sewn patches for $1 more per hat.
Is there a setup fee for leather patches?
No. The laser cuts and engraves from your vector art directly. There is no plate, die or digitizing charge.
Can I mix patch hats and embroidered hats in one order?
Yes. Each decoration is priced on its own quantity, so 48 patch hats and 48 embroidered hats are two 48-71 tier lines on one quote.