Custom ball caps and flat-visor hats are popular gift items for a variety of occasions, and having an Epilog Laser machine allows you to personalize these items at the touch of a button! This sample club 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 we got the materials, laser parameters, and more! The best part? No sewing or stitching involved - watch the video above and see how we did it!

Download Graphics

Materials Needed

We used a Fusion M2 40 120w:

Leather Patch Engrave: Raster // Speed 100% // Power 75% // 300dpi

Leather Patch Cut: Vector // Speed 80% // Power 100% // 50F

Hat Bill Engrave: Raster // Speed 100% // Power 30% // 600dpi

Hat Bill Cut: Vector // Speed 50% // Power 60% // 20F

Step 1: Prepare Artwork

Download the graphics above and import it into your graphic software. Make adjustments as necessary.

Design files for laser engraving leather hat patches

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.

laser engraving leather hat patches in machine
laser engraving adhesive wood veneer hat brims

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.

Applying the adhesive leather hat patch to the front of the cap.
close up of laser engraved  hat accessories

Where can you sell custom hats and patches?

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

Get Free Brochure & Samples

Receive brochures and samples, and get more info from us or your local distributor.

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