Are embroidered or patch hats better?

Neither is better across the board. Embroidery is the classic, the simplest to order and priced instantly online. Patches give a bold badge look, handle fine detail as woven patches, and the same patch can go on other products too.

What is the minimum order for custom hats?

12 pieces per design for embroidered hats. Custom patches start at 50 pieces.

How much do embroidered hats cost?

About $4.55 per cap for the embroidery at 72 caps, for a logo up to 5,000 stitches, plus the blank cap (from about $2.51) and a one-time $49 digitizing setup that reorders skip.

Do embroidered logos last?

Yes. Stitched thread is the standard for headwear because it lasts the life of the hat, with no ink to crack or peel.

Can I use the same patch on other products?

Yes. Patches can be sewn or heat-applied to jackets, bags and more, and come with iron-on, sew-on, peel & stick, plastic or hook & loop backing.

Embroidered Hats vs Patch Hats: Which to Pick

There are two classic ways to put your logo on a cap: embroider it directly onto the hat, or make a custom patch and apply it to the front. Both look great and both last. They differ in look, detail, minimums and cost.

The short answer

Embroidered hats are the go-to for most logos: stitched straight into the cap, priced instantly online, from 12 pieces.
Patch hats give a bold, badge-style look, woven patches hold fine detail, and the same patch can go on caps, jackets and bags. Patches start at 50 pieces.

Embroidered hats

Your logo is digitized into a stitch file, then sewn straight into the front of the cap. It's the standard for headwear: raised, textured, and it lasts the life of the hat. Bold, simple logos stitch best; tiny text and hairline details are where embroidery reaches its limits.

Pricing is per cap, set by the stitch count (roughly, how much thread your logo takes) and the quantity. A one-time digitizing setup of $49 covers designs up to 15,000 stitches, and reorders skip it. The embroidery runs about:

12 caps: $9.63 per cap for a logo up to 5,000 stitches, $11.91 up to 10,000.
72 caps: $4.55 per cap for a logo up to 5,000 stitches, $6.13 up to 10,000.
216 caps: $3.50 per cap for a logo up to 5,000 stitches, $4.73 up to 10,000.
720 caps: $2.98 per cap for a logo up to 5,000 stitches, $3.94 up to 10,000.

The blank cap is on top, from about $2.51 (Richardson, YP Classics, Port Authority, Valucap and more). Embroidered hats take 14–15 business days after you approve your proof.

Patch hats

A patch is made on its own (embroidered, woven or PVC), cut to shape, then sewn or heat-applied to the cap. The finished border gives a clean, structured look, and shapes go well beyond a rectangle: circles, ovals, shields and custom die-cut outlines. Woven patches render fine detail a stitched one can't, which makes them the answer for small text and intricate logos.

Custom embroidered patches, made separately and then applied to the cap.

Embroidered patches are priced instantly in our patch builder from 50 pieces, with a $45 setup that covers up to 6 thread colors. A 3″ patch at 75% stitch coverage runs about $3.26 each at 50, $1.85 each at 100 and $1.05 each at 300, before backing. Patches take 11–13 business days to make, or 7 with rush.

Patch caps are quoted rather than priced online: contact us with your patch and the caps you want, and we'll price the finished hat.

How to choose

12–49 caps: embroidery. Patches start at 50.
A bold, simple logo: embroidery, the classic and the simplest to order.
Fine detail or small text: a woven patch.
A badge or vintage look: a patch.
One logo across caps, jackets and bags: patches, so every item carries the same piece.
Beanies: either works. Custom beanies take embroidery or a woven patch.