The Hat Patch Craze: Trending Styles, Maker Insights & the Power of Lonestar Adhesive

The hat patch craze has exploded across the personalization world, and it’s opening up big opportunities for makers to tap into a fast-growing trend. Whether you’re working with our Saddle Collection Leather-Like Sheet, FlexiBrass®, LaserMax® Tri-Layer, or two-tone acrylic, there’s no shortage of eye-catching materials that can be transformed into standout hat patches. The best part? With Lonestar Durrabull Adhesive, applying those patches is quick, clean, and ultra-secure—no sewing, no stress. It’s never been easier to turn your favorite blank materials into top-selling hat patches your customers will love.

First, let’s take a look at some of our most popular materials for hat patches. From metallic and leatherette finishes to bold acrylics and layered engraving sheets, JPPlus offers a wide range of blanks to fit any style or project.

Production Tips to Maximize Efficiency and Quality

To keep up with demand and maintain a consistent product, batching your production is key. Pre-cut your patches in bulk, apply Lonestar Durrabull Adhesive sheets ahead of time using a heat press or hat press, and store them flat in labeled folders or boxes. This way, when an order comes in, you can quickly press the patches onto hats without needing to stop and prep adhesive each time. Using a hat press ensures even pressure and proper bonding on curved surfaces, resulting in durable, professional-quality patches that withstand wear and washing.

Organize your materials by type and color, and keep a record of heat press settings for each material—this reduces guesswork and speeds up training new staff or scaling your production line. Efficient workflow combined with the reliable performance of Lonestar Durrabull Adhesive creates a seamless process from blank to finished hat patch.

Unlocking Profit Potential with Scrap Materials

One of the biggest advantages of adding hat patches to your product lineup is the low material investment—especially if your business already works with substrates like leatherette, acrylic, or engraving plastics. Off-cuts and remnants that might otherwise go unused can be repurposed into high-demand, high-margin hat patches. When it comes to applying those patches, Lonestar Durrabull Adhesive is a top choice in the personalization industry. Known for its strength, clean finish, and ease of use, it’s become the go-to solution for makers producing custom hat patches at scale. Simply cut your patch material, apply Lonestar Durrabull Adhesive (shiny side down) with a heat press like the Stahls Hotronix 360 IQ Hat Press, let cool, then press the finished patch onto the hat with firm pressure. No sewing, no mess—just a secure, professional bond every time. It’s the easiest way to scale your hat patch production while keeping quality consistent. Need help using Lonestar Durrabull Adhesive? Check out this easy to follow tutorial!

As the hat patch trend continues to gain momentum, now is the perfect time for personalization businesses to expand their product offerings and tap into this lucrative market. With JPPlus’s diverse selection of premium materials and the trusted reliability of Lonestar Durrabull Adhesive, makers can create stunning, durable patches that appeal to a wide range of customers. By incorporating efficient production techniques and smart use of scrap materials, you’ll not only boost profits but also deliver high-quality custom patches that keep customers coming back. Embrace the hat patch craze today and watch your business grow with this versatile, on-trend product.