How Our Custom Leather Patch Hats Are Made in Canton, GA
Every hat that leaves The Hat Bar of Georgia is made right here in Canton, GA. We’re a family business run by Phil Heath and his wife, Brandy, and custom patch hats are what we do every day, whether at our shop, at a festival or at a private event. If you’ve ever wondered how a blank cap becomes a custom leather patch hat, here’s a look at the process from start to finish.
Step 1: Pick Your Hat
Everything starts with the hat. We keep more than 2,000 hats on hand and are a dealer for hundreds of brands, so there’s plenty to choose from: classic trucker hats, rope hats, flat bills, relaxed dad hats, 7-panels, ponytail caps and more, in a wide range of colors and camo patterns.
A few things to consider when you choose:
- Fit and profile. Some people like a structured, higher crown; others prefer a low-profile or unstructured cap.
- Color contrast. A leather patch stands out on dark and mid-tone hats, while a full-color patch can pop on lighter colors.
- Where it will be worn. A hat for a work crew, a hunting trip, a wedding party or a company event might each call for a different style.
If you’re not sure, just ask. Helping people find the right hat is part of the job.
Step 2: Pick or Design Your Patch
Next comes the patch. You can choose from our collection of more than 5,000 patches, start from one of our ready-made designs, or bring your own idea. That could be a business logo you own, a family name, a favorite saying, an outdoors scene or a design for a special occasion.
We offer two main patch types:
- Leather patches are engraved, giving a classic look with natural contrast between the surface and the engraved design.
- Full-color patches are printed, which works well for detailed artwork, multiple colors or photo-style designs.
Step 3: Get Your Free Mockup
Before anything is made, we create a free mockup so you can see your design on the hat you picked. This is the time to adjust the size, placement, wording or hat color until it looks right. Mockups are always free, and we don’t charge setup fees.
For businesses, teams, churches, families and event groups, this step also makes it easy to get approval from everyone before the order goes into production.
Step 4: Engrave or Print the Patch
Once you approve the mockup, we make your patch. Leather patches are engraved with your design, and full-color patches are printed. Either way, the design is produced to match the mockup you approved.
Step 5: Contour-Cut the Patch
Next, the patch is cut to shape. A patch can be a classic rectangle, circle or oval, or it can be contour-cut to follow the outline of the design itself, such as a longhorn skull, a bow, a cross or a script name. Contour cutting is a big part of what gives a custom patch hat its finished, one-of-a-kind look.
Step 6: Heat Press the Patch onto the Hat
Finally, the finished patch is applied to the hat with a heat press. We position it on the front of the hat and press it into place, and your custom hat is ready to wear.
Want to See It in Person? Visit the Live Hat Bar
The same process runs at our live hat bar. We bring it to festivals, shows, and corporate and private events, where guests pick a hat, pick a patch and watch their custom hat get made on the spot. It’s a great fit for company gatherings, customer appreciation days, weddings, birthdays and community events. If you’re planning an event in North Georgia or elsewhere in the Southeast, ask us about booking the hat bar.
Order One Hat or a Whole Batch
There are no minimums on patch hats, so you can order a single hat for yourself or outfit an entire crew. If you’re looking for embroidery instead, we offer that too, with a 12-piece minimum on hats and apparel.
Let’s Make Your Hat
Ready to start? Send us your idea through our contact form, call us at (770) 905-7361, or email thehatbarllc@gmail.com. We’ll help you pick the right hat and patch and send a free mockup, and we’ll make it right here in Canton, GA.