The Ultimate Hat Decoration Guide: Every Method Explained

Hats are in hot demand. Help your brand stand head and shoulders above the competition with unique decoration techniques. With this comprehensive guide by your side, you’ll be able to design your next big seller. Let’s get started.

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One Hat, Every Decoration Method:

Looking for a hat style to get started with? While almost all of our hats will work for the decoration techniques in this guide, we recommend giving the Garment-Washed Cap a try. Not only is it super versatile, it works with many methods and comes in a wide variety of colors so you can make your artwork pop.

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Decoration Methods:

Traditional Embroidery

Embroidery is likely the hat decoration technique you are most familiar with. With this method, your artwork is digitized (converted into a digital file that tells an embroidery machine how to stitch the design). Then, artwork is stitched on each hat, creating an embroidered design with a three-dimensional feel – a crowd pleaser for traditionalists and trend-setters alike.

  • Recommended Products: All hat styles

  • Recommended Locations: Front, back and sides are best

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PVC Patch

If your clients like patches but want extremely crisp graphics, the PVC Patch will be a great fit. Rather than being constructed with thread, these textured patches are made from a flexible, abrasion-resistant plastic and applied to products using heat. The result? Durable decoration and vibrant colors that take your brand headwear to the next level.

  • Recommended Products: Cotton-based styles

  • Recommended Locations: Front and back are most popular

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Heat Transfer

This decoration technique is both affordable and versatile for many types of artwork. Graphics are printed on a transfer substrate that's applied directly to hats using heat. Because graphics are printed instead of sewn, there are few limitations to what your clients can do. Complicated or intricate designs? Not a problem for this method. Bonus tip: Try imprinting on top of hat visors. This uncommon location is sure to get logos noticed.

  • Recommended Products: Cotton- and poly-based styles

  • Recommended Locations: Any location, including the visor top

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Embroidered Patch

Looking for a little retro flavor? This next patch style will deliver. Just like the army surplus and varsity jackets of your youth, this decoration method brings with it a healthy dose of nostalgia. Like traditional embroidery, your artwork is digitized and stitched onto hats, but the merrowed edge provides a throwback vibe audiences of all ages will appreciate. Talk about rad!

  • Recommended Products: All hat styles

  • Recommended Locations: Center front is best

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Sublimated Patch

Got complicated or full-color artwork? Sublimated patches are the way to go. Unlike other methods (like embroidery) that have limitations on the artwork that can be used, sublimation allows you to reproduce almost any design, no matter how intricate. If you want to decorate using full-color graphics or complex designs, this method will allow that and then some. Add in merrowed edges and bold colors, and you’ve got yourself one seriously impressive hat promo.

  • Recommended Products: All hat styles

  • Recommended Locations: Center front is best

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Leather Debossed Patch

Suede accents are all the rage. Help you brand keep up on current trends with impressive leather debossed patches. Applied using heat and crafted with sturdy leather, this high-end decoration method is built to last and sure to please. Best of all: debossing are made with precise, cutting-edge CO² laser technology, so you can be assured your artwork will be super sharp, down to the smallest details.

  • Recommended Products: Cotton- and poly-based styles

  • Recommended Locations: Any location

Mick Pennington