Hat Patch Size Guide: What Size Patch for a Richardson 112 and Other Caps
Patch sizes that fit a Richardson 112 and other cap styles, our blank sizes by shape, and how many patches you get from one sheet.
Quick answer
On a structured mid-profile trucker cap like the Richardson 112, most leather patches are 2.5"–3.5" wide and 2"–2.5" tall. Our pre-cut rectangle and hexagon blanks are 3.5" wide and 2.1"–2.2" tall, which fills the front of a 112 without running onto the side panels. On a low-profile cap, go shorter (about 2" tall, or a 2.3" circle). On an unstructured dad hat, go smaller, around 2.5" wide.
Blank Full-Grain Leather PatchesFrom $3.20
Leatherette Blank Thick PatchesFrom $2.80
Custom Leather Patches$4.90
Laser Alignment Tool for DuoForge Hat Press$39.00
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Patch sizes by shape
These are the sizes of our pre-cut full-grain leather blanks and leatherette blanks. Both lines use the same shapes and sizes.
| Shape | Size | Works well for |
|---|---|---|
| Rectangle | 3.5" × 2.1" (90 × 53 mm) | Wordmarks and logos with text; most structured trucker caps |
| Hexagon | 3.5" × 2.2" (90 × 57 mm) | Outdoor, ranch and hunting brands; a popular look on a 112 |
| Oval | 3.5" × 2.1" (90 × 53 mm) | Softer, vintage-style logos |
| Cattle tag | 2.7" × 2.1" (69 × 55 mm) | Western brands and smaller caps |
| Circle | 2.3" (60 mm) | Round logos, low-profile caps |
| Square | 2.3" × 2.3" (60 × 60 mm) | Monograms and badge-style logos |
For custom patches we engrave for you, the maximum is 3.54" wide × 2.55" tall (90 × 65 mm), in 17 shapes.
Patch size by cap style
| Cap | Front | Patch size that usually works | Notes |
|---|---|---|---|
| Richardson 112 and other mid-profile truckers | Structured, 6 panels, seam down the middle | 2.5"–3.5" wide, 2"–2.5" tall | Center the patch over the front seam |
| Richardson 168 (7-panel trucker) | Structured, center front panel | Same as the 112 | No seam under the middle of the patch |
| Richardson 112FP (5-panel) | One-piece front | Same as the 112 | No seam at all; very clean background |
| Low-profile truckers such as the Richardson 115 | Lower crown (about 3" vs about 3.5" on the 112) | Around 2" tall, or a 2.3" circle or square | A tall patch crowds the top of the crown |
| Unstructured dad hats | Soft front, no backing | Around 2.5" wide | Support the front from inside when pressing |
Crown heights vary by brand and even by listing, so treat these as starting points and hold a paper cutout against your own cap before you engrave a batch.
How to size a patch for your cap
- Cut a paper template in the shape and size you're considering.
- Hold it on the front of the cap, centered side to side. The patch should sit on the front panels only, not wrap onto the side panels.
- Check the bottom edge. Leave clear space above the visor seam so the press can sit flat and the patch doesn't ride on the seam.
- Check the top edge. The patch should stay on the flatter part of the front, below where the crown starts to curve back.
- Look from a few feet away. A patch that looks big in your hand often looks right on a head.
How many patches you get from one sheet
One 12" × 24" leatherette sheet with adhesive costs $13. With a 1/8" gap between patches in a simple grid:
| Patch size | Patches per 12" × 24" sheet | Material cost per patch |
|---|---|---|
| 3.5" × 2.1" | 30 | about $0.43 |
| 3" × 2" | 35 | about $0.37 |
| 2.3" × 2.3" | 36 | about $0.36 |
| 2.5" × 2" | 45 | about $0.29 |
Nesting round or angled shapes can fit more. Buying leatherette by the yard (26" wide) brings a 3.5" × 2.1" patch down to about $0.33.
Design tips for small patches
- Keep text bold. Thin script and small text are the first things to blur at patch size. Engrave a test on a scrap before a full batch.
- Leave a margin between the artwork and the edge of the patch, especially on stitched blanks, so the stitching doesn't run into the logo.
- Match the shape to the logo. A round logo in a rectangle wastes space; put it on a circle or a hexagon.
FAQ
What size patch fits a Richardson 112?
Most patches on a 112 are 2.5"–3.5" wide and 2"–2.5" tall. Our 3.5" × 2.1" rectangle and 3.5" × 2.2" hexagon are sized for it.
What's the biggest patch I can put on a trucker hat?
Keep it on the front panels: once a patch wraps onto the side panels, it's hard to press evenly and the edges tend to lift. For our custom patches the maximum is 3.54" × 2.55".
How do I keep patches straight on every hat?
Use a laser alignment tool or a strip of heat-resistant tape, and center the patch on the front seam or center panel.
What heat press settings do I use once the patch is sized?
See the hat patch heat press chart for leather, leatherette, PVC and acrylic on each type of press.
