Making Custom Hat Patches with a Laser: A step-by-step guide
If you're looking to make your own custom leatherette hat patches with a laser engraver, this post walks you through everything — from design to final press. This is the same process I used in the YouTube video embedded above, but with a little more detail and a couple extra tips that didn’t make the cut.
We’re using the xTool P2 laser and a simple heat press setup for this one, but the workflow is pretty much the same no matter what gear you’re using.
What You’ll Need:
Laser engraver (xTool P2 in this case)
Leatherette material – I used Lone Star Adhesive-backed leatherette (gray, reveals black)
Heat press – basic hat press or equivalent
Vector design software – I used Inkscape (it’s free)
Degreaser + soft brush (for post-processing)
Optional: Silicone mat, microfiber cloth, thermal tape
Step 1: Prepping the Leatherette
First thing: get your leatherette material flat and secure on the laser bed. These sheets tend to curl a little, so I hold the edges down with magnets to keep it flat for measuring and engraving. Make sure your material is totally within the engravable zone before you start lining anything up.
Step 2: Converting Your Design to SVG
For this project, I used a Louisiana map image with a splatter effect. I dropped it into Inkscape and used the Path > Trace Bitmap tool. Brightness cutoff usually works fine — in this case, the default 0.450 threshold picked up everything nicely.
Once you’ve traced your image and deleted the original, resize the canvas to your selection and save it as an SVG. That’s what you’ll import into your laser software (in this case, xTool Creative Space or XCS).
Step 3: Sizing & Offsetting the Patch
After pulling the design into XCS, measure your hat to figure out your max patch size. Mine ended up being about 55mm wide, which fits most structured caps without looking goofy.
Next, use the Offset tool to generate a cut line around your graphic. I used a 1mm offset and selected “outer shapes only” to avoid all the little islands inside the image. Color the engrave black and the cut line red (or whatever helps keep it straight in your mind).
Step 4: Engrave & Cut Settings (xTool P2)
Engrave:
Power: 26%
Speed: 325mm/s
LPI: 180
Cut:
Power: 95%
Speed: 20mm/s
Passes: 1
These settings work great on this particular leatherette, but you’ll definitely want to run a test grid if you're using a different brand or color.
Step 5: Clean-Up
Once it’s out of the machine, hit the patch with a degreaser and a toothbrush (motorized or manual — your call). Rinse it off and pat dry with a microfiber cloth. Pay special attention to the edges where soot tends to build up from the laser. If you skip this step, it will transfer to your hat when pressed.
Let it dry completely — overnight if you can — especially if you rinsed it heavily. Trapped water can cause bubbling or blowout around the edges during pressing.
Step 6: Pressing the Patch
I used a Decky hat and a budget-friendly heated hat press setup (roughly $150 + a silicone heated platen from Patch Crafters). Here’s the quick rundown:
Preheat your patch area with light pressure for 10–15 seconds
Line up the patch with center seams and apply firm pressure
Press at 290°F for 60 seconds
Use a silicone sheet or cloth to avoid scorching
Double-check corners after pressing and repress if needed
Pro tip: if you’re working with unstructured hats, give it a little curve while it’s still warm to help it fit more naturally when worn.
Optional Finish: Resolene
If you’re using raw leather or want a more uniform finish, a light coat of Resolene will help seal the engraving and reduce visible burn lines. I skipped it on this one because the leatherette already had a decent finish, but it’s a good trick to keep in your pocket.
Final Thoughts
Making your own leatherette patches is easier than it looks — and a great way to start customizing hats, especially if you’re thinking about selling them. You can start simple with one-layer vector graphics like this, then branch out into layered designs, textures, and different color combos.
If you found this helpful, check out the video at the top of the page for the full walkthrough. And if you’ve got questions or want to see a more advanced patch build in a future post, leave a comment or hit me up.
