Custom Patch Hats vs. Printed Hats: Which One is Right for Your Brand?

Thinking of standing out? Custom hats are a foolproof way to get noticed while giving your audience something practical and useful. Whether it's for promotions, events, sportswear, or uniforms, custom hats can add flair to any outfit.

But how do you know which decoration method to choose? Should you go for a custom patch hat or a printed hat? Don't worry, this guide from LogoSportswear breaks down their key differences to help you find the best fit.

What are Custom Patch Hats?

Custom patch hats feature a design or logo on a patch which is typically placed on the front panel of the hat. These patches are made separately and can come in various shapes, sizes, and materials. They also have a bold, raised, and textured look that adds character to any wearable merchandise. Custom patch hats are often used by clothing brands and breweries, clubs, and event organizers. They also make for great team uniforms, outdoor gear, and workwear.

Types of Patches Used

Embroidered – Provides a classic and textured look. The design used on the patches are thread-based and stitched onto a fabric backing.
Leather – Great for luxury and outdoor-themed brands. The design on leather patches is engraved using a laser, which creates a premium yet rustic feel.
Woven – Thread-based like embroidered patches, except that they are smoother, more detailed, and more polished.
PVC – Durable, waterproof, and made from flexible synthetic material similar to rubber. This type of patch offers a 3D, modern, premium look ideal for various shapes and designs.
Sublimated – Provides the best of both worlds. These patches are more detailed than embroidered or leather patches. The design is directly printed onto a fabric patch, giving a flat printed look with the structure and durability of a patch.

How Patch Hats are Made Patch hats are made by designing patches using your preferred material. These patches are then attached onto the hat's fabric through heat-press, sewing, or adhesive, depending on the type of durability you want.

What are Custom Printed Hats?

Custom printed hats are created by applying ink directly onto the hat's fabric. This decoration method skips the patch entirely and goes straight to the surface. Printed hats feature a flat, smooth finish that is perfect for detailed and colorful designs, small texts, and fine lines. They're also best used as merch, giveaways, school spirit wear.

How Printed Hats are Made
To make a printed hat, digital designs are printed on a special transfer film. Then, through Direct-to-Film (DTF), the design is applied to the hat using heat and pressure from a heat press.

Key Differences Between Custom Patch Hats and Custom Printed Hats

Aside from how custom patch hats and printed hats are made, they also have various features that set them apart. Check out the comparison table below:

Patch Hats	Features	Printed Hats
Has a raised, textured, premium look. Feels more "handmade" and stylish	Look and Feel	Smooth, flat, and modern. Feels sleek and professional.
Patches are either sewn or pressed	Design Method	Designs are printed on a heat transfer film and applied through a heat press
Ideal for bold, simple logos or designs; can be limited to patch size, shape, and stitching detail	Design Detail	Detailed, colorful designs, gradients, photo-realistic graphics
Durable, holds up after many washes, but the attachment might also loosen over time	Durability	Has good durability but the print might not last long after frequent washing
More expensive due to patch creation and sewing	Cost	Lower cost, best for limited budgets and large orders
Slower process as the patches need to be made first, then attached	Turnaround Time	Faster to produce because of digital printing methods
Premium, professional, and rugged, ideal for breweries, outdoor gear brands,	Brand Perception	Trendy, creative, modern, and fun, best for events, giveaways, festivals, fashion-forward brands

Look and Feel
Patch hats have a bold and premium appearance. They have a raised, textured, 3D look and might seem a bit heavier because of the patch attached to the hat. Meanwhile, printed hats offer a clean and modern finish that gives off a sleek and professional look.

Design Method
Patch hats are made by creating a separate patch that is then attached to the hat through sewing or heat pressing. On the other hand, printed hats are created through Direct-to-Film heat transfer.

Design Detail
Patch hats are best for bold, simple logos or designs. They're not recommended for small text or intricate details due to patch size limitations, shapes, and stitching detail. Printed hats can handle detailed and complex designs, including multiple colors, gradients, and photos.

Durability
Patch hats are highly durable. They can withstand multiple washes and won't easily fade. However, the attachment or adhesive may loosen over time. Printed hats are less durable compared to patch hats, as their design might not last after frequent washing.

Cost
Patch hats are more expensive because of how the patches are made and attached. They're more ideal if you only need a small batch of custom hats. Meanwhile, printed hats are more affordable. They have minimal setup costs and are great for smaller budgets and large orders.

Turnaround Time
With patch hats, you can expect a longer lead time. The patches need to be made first before they are attached to the hat's fabric. As for printed hats, they have a faster turnaround due to digital printing and are suitable for rush orders.

Brand Perception
Patch hats reflect a brand that is premium, professional, and rugged, making them ideal for breweries, outdoorsy brands, and workwear. On the other hand, printed hats are trendy, fun, and creative, perfect for brands that are expressive, modern, and casual.

Pros and Cons of Patch Hats and Printed Hats

Both patch hats and printed hats have their own upsides and tradeoffs. Below are their pros and cons to help you decide which one to get:

Patch Hats

Pros

Has a premium and professional appearance
Durable and long-lasting
Ideal for simple and bold logos
Textured look makes your brand stand out

Cons

May be more expensive than printed hats
Slower turnaround time
Limited design options
May feel heavier and bulkier due to the patches

Printed Hats

Pros

More budget-friendly, especially with bulk orders
Faster to produce and best for large or rush orders
Great for complex and detailed designs
Lightweight and easy to wear

Cons

Not as durable after frequent washing
Less tactile or textured feel so the design might not stand out as much
Doesn't give off a premium feel
May need extra care when washing and drying

Which One Should You Choose?

Choose patch hats if:

You have long-term promotions and want a premium, long-lasting product
Your hat will feature a bold and simple design
Your brand is high-end or outdoorsy
You're in no rush and only need a small batch of custom hats

Choose printed hats if:

You need them as soon as possible
You're working on a limited budget
Your brand is fun, creative, or artsy
Your design is detailed and colorful
You're using them for giveaways, events, or one-off events

Conclusion

There's no wrong choice when it comes to the best custom hat, and the right one ultimately depends on your preferred design, budget, and brand guidelines. Choose printed hats if you want a custom hat that's trendy, playful, and affordable or if you're experimenting with creative designs. Lastly, patch hats are great if you prefer something premium, long-lasting, and stylish.

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