Try This: Laser Engrave Leather Hat Patches

Custom ball caps and flat-visor hats are popular gift items for a variety of occasions, and having a laser machine allows you to personalize these products at the touch of a button. This project covers laser engraving leather hat patches, as well as engraving and cutting custom wood veneer visor covers for caps. Read on to learn where to get the materials, laser parameters, and more. The best part? No sewing or stitching involved!

Materials needed:

• Leather adhesive patches
• Adhesive-back wooden veneer
• Ball caps
• Flat visor caps
• Laser system

We used a Fusion M2 40 120w:

• Laser patch engrave: raster; speed: 100%; power: 75%; 300 DPI
• Leather patch cut: vector; speed: 80%; power: 100%; 50F
• Hat bill engrave: raster; speed: 100%; power: 30%; 600 DPI
• Hat bill cut: vector; speed: 50%; power: 60%; 20F

Step 1: Prepare Artwork

Download the graphics we used and import into your graphic software (you can also design your own if you choose). Make adjustments as necessary.

Step 2: Send to the Laser

Send the job to the laser with the correct parameters for your machine wattage. We recommend using the bottom-up laser engraving feature to avoid excess smoke/residue settling into the engraved portions of your design.

Step 3: Assembly

When laser engraved, leather can produce more smoke/residue than other substrates, so we recommend lightly wiping off the patches with a damp cloth when you’re done to remove any residue left behind.

Lastly, remove the protective backing from the patch and brim and adhere them to your caps.

Where can you sell custom hats and patches?

• As wedding party gifts
• In online shops
• As custom birth or anniversary gifts
• In gift shops