How to Iron a Patch on a Hat: The Complete Guide

Key Takeaways

• ◆ Learn the exact step-by-step process for heat-applying patches to hats.
• ◆ Pro tips on patch placement, iron settings, and avoiding damage.
• ◆ Which patch types work best with heat vs. sewing?
• ◆ Tools and tricks used by professionals for long-lasting results.

If you’ve ever wanted to take a plain hat and make it your own, learning how to iron a patch on a hat is a skill worth having. Whether it’s a custom patch for your small business, a team logo, or a fun design for your baseball cap, a well-applied patch can make a simple accessory something you’ll want to wear every day.

Want a shortcut? At The Monterey Company, we’ve been making and applying custom patches to hats, jackets, and more since 1989. From embroidered patches to PVC, leather, and more. We can create your design, apply it with professional equipment, and ship it straight to you!

Get Started Here with a Free Quote.

In this guide, we’re going to break down everything you need, from the tools and steps to expert tips, so your patch stays put and looks fantastic. Plus, I’ll share tricks we use in our shop when heat-applying custom iron-on patches so they last for the long haul.

⬇ Prefer Video? Please check out our YouTube video below ⬇

Why Ironing a Patch on a Hat Works So Well

Ironing is one of the most popular attachment methods for patches because it’s fast, clean, and doesn’t require a sewing machine. Using custom iron-on patches means you can avoid the mess of fabric glue and still get a professional look. The key? Controlling your heat, pressure, and patch placement.

Some patch types, like an embroidered patch or a customized PVC patch, need extra care during the heat application process. That’s why using the right iron temperature in the form of a hat press makes all the difference.

Step-by-Step Guide to Ironing a Patch on a Hat

Here’s the step-by-step process we use when applying patches to hats in our shop.

Step 1: Gather Your Necessary Materials

To get the best results, you’ll need:

• ✓ A hat press or a household iron (if you don’t have a press)
• ✓ Your patch (embroidered patch, PVC, or even chenille letter patches)
• ✓ Pressing cloth/foam or a thin cloth for extra protection
• ✓ Thermal tape (for keeping the patch from shifting)
• ✓ Foam pad (helps keep the hat’s shape)
• ✓ Of course, your favorite hat!

If you are looking to invest in a heat press for hats, we highly suggest the Stahls Fusion IQ 360. We love the option for top and bottom heat, saved heat settings, and the seamless adjustable pressure. They are not cheap and are more geared to embroidery and print shops. For the average DIY’r that is looking to press a handful of hats, I suggest a household iron (that can be tricky) or reaching out to a vendor. The Monterey Company does offer sewing and heat application. Click here if interested.

Step 2: Check the Hat’s Fabric and Care Label

Before you apply direct heat, read the care label on your hat. Some fabric types, especially delicate fabrics (spandex, suede, velvet…), can burn or shrink. If you’re working with a bucket hat, cowboy hat, or fitted hat, you’ll want to use a lower heat setting and more extra protection between the iron and the fabric.

Step 3: Preheat the Hat

Think of this like preheating your oven before making pizza. Preheating removes moisture from the hat’s fabric and helps the iron-on backing on the patch bond better. Use high heat for sturdy fabrics like cotton, or a gentler setting for more delicate materials.

Step 4: Position Your Patch Perfectly

Patch placement is where most DIYers go wrong. Lay your hat on a curved, stable surface (preferably not a flat surface) or secure it into your hat press. If you’re working on a classic ball cap or letterman jacket, make sure there are no wrinkles. Use thermal tape to hold the patch exactly where you want it so it doesn’t slide during pressing.

🙌 Pro tip: To keep the edges of the patch smooth and aligned, always use thermal tape for alignment. This is the thermal tape we use that we order from Uline: Kapton Thermal Tape. It’s cheap and will last for many heat press runs. Amazon offers some great thermal tape options as well.

Step 5: Add Foam and Pressing Cloth

If you’re using a hat press, place a thin foam pad inside the crown of the hat. This keeps the shape intact and prevents scorching. A pressing cloth, thin cotton cloth, or even a piece of a cloth T-shirt will add extra protection between the patch and the hot iron.

Many times, I have missed this step and ended up adding heat marking or burn marks to the hat.

Step 6: Press the Iron or Use a Hat Press

If you have a hat press like the Hotronix IQ 360 we use, set the iron temperature based on the type of patch. For embroidered iron patches, we often go with around 280°F on top and 320°F on bottom for about 50 seconds.
If you’re using your own iron:

1. Place the pressing cloth over the patch.
2. Press the iron firmly (don’t slide it) to apply direct heat.
3. Hold for 20–30 seconds for small patches, or up to 50 seconds for a large patch.

Looking to order custom patches? We have you covered! Since 1989, The Monterey Company has been the leader in patch production, everything from embroidered, leather and even PVC Patches.

CLICK HERE TO GET STARTED

Step 7: Let the Patch Cool

This step is huge. After pressing, let the patch cool before touching it. This allows the adhesive to set and cure thoroughly. If you pull the hat too early, you risk the patch peeling or tilting off-center from the hat. Too often, I have been impatient, heating and applying dozens of hats, and packaged them too early, not giving them the 15 minutes to cure.

Patch Types and Heat Application Tips

Not all patches react the same way to heat. Here’s a quick breakdown:

Embroidered Patch

Classic choice for DIY projects, uniforms, and scout patches. Can handle higher heat but benefits from extra protection. One of our best sellers, and very heat resistant. Learn more

PVC Patch

Since it is more sensitive to direct heat, use more bottom heat than top heat if you have a hat press. Don’t forget the foam layer with PVC patches. Learn more

Letter Patches

Perfect for letterman jackets, team gear, or even tote bags. Line them up carefully for even spacing. Heat-applying leather patches can be tricky. Learn more

Velcro Patches

Can be heat-applied if they have an iron-on backing on the backside of the hook portion of the patch. Direct sunlight can break down the glue over time. Leather more

Pro Tips for Best Results

• 1. Always test on scrap fabric or an old t-shirt before working on your final type of hat. Remember, practice makes perfect. You don’t want to destroy too many hats learning.
• 2. For DIY patch projects, patch glue can be used on tricky fabrics that are heat-sensitive. Fabrics like velvet, suede, and even genuine leather can be sensitive to direct heat.
• 3. Avoid the washing machine for 24 hours after applying. Allow the glue to fully setup and bond to the patch and the hat.
• 4. Keep your hat out of direct sunlight for the first day to protect the bond. Direct sunlight can remelt the glue and cause an improper application.
• 5. Proper care (like gentle hand washing) will extend the life of your patch. I avoid washing machines and dryers altogether.

When to Skip the Iron and Sew Instead

If you’re working with delicate fabrics, collectible patches, or a cowboy hat with a special finish, sew-on patches might be the better option. Hand sewing or using a sewing machine offers a more permanent hold without the risk of heat damage. Sewing is the ultimate way to secure your patches to hats. Make sure to use a skilled seamstress, or reach out to The Monterey Company and ask about our sewing service.

Final Thoughts

Learning how to iron a patch on a hat opens up endless customization options. From DIY guide projects with custom iron-on patches to professional heat transfers (DTF transfers), the process is simple once you know the best methods.

At The Monterey Company, we’ve been making patch hats and helping customers with a wide range of fabric types since 1989. Whether you’re adding a single patch to a denim jacket or outfitting an entire team, we can make it happen! Ask for patch samples, we are happy to send you samples with free shipping.

Got questions about the ironing process or want us to handle it for you? Drop us an email address or phone number through our contact page, and we’ll help you create something you’ll cherish for years.

Eric Turney is the President at The Monterey Company. Connect with me on LinkedIn!