If you're researching custom leather patch hats, you've probably noticed that different companies use different methods to put your logo on leather.
The two most common options are heat-stamping and laser engraving. Both can produce a decent-looking patch. But they work in fundamentally different ways—and those differences affect the quality, durability, and overall look of the finished product.
This post breaks down how each method works, the pros and cons of each, and why we chose heat-stamping for everything we make at Byward Outfitters.
How Laser Engraving Works
Laser engraving uses a focused beam of light to burn away the surface of the leather. The laser vaporizes a thin layer of material, revealing a lighter colour underneath and creating the design.
It's a precise process. Modern laser machines can reproduce intricate details and fine lines with accuracy. The equipment is largely automated, which makes it fast and relatively inexpensive to operate at scale.
That's why a lot of custom hat companies use laser engraving. It's efficient. You can load a file into the machine, run a batch of patches, and move on to the next order without much hands-on work.
But efficiency comes with trade-offs.
The Downsides of Laser Engraving
Surface burning. Laser engraving works by burning the leather. That's literally how it creates the design. Depending on the settings and the leather quality, this can leave edges looking scorched, uneven, or slightly discoloured. Some patches end up with a yellowish or brownish tint around the engraved areas.
Flat appearance. Because the laser removes material from the surface, the result is essentially a shallow etching. There's no real depth or texture to the design. It looks printed on rather than pressed in.
Durability concerns. The engraved surface is thinner than the surrounding leather. Over time—especially with regular wear—the design can fade, smooth out, or become less visible. The burned edges are also more prone to wear than compressed leather fibers.
Smell. This is a minor point, but laser-engraved leather often has a faint burned smell, at least initially. It fades over time, but it's noticeable when the patches are fresh.
None of this means laser engraving is terrible. For certain applications—especially high-volume orders where cost is the main concern—it's a reasonable option. But if you're looking for a premium finish that holds up over years of wear, it's worth understanding what you're getting.
How Heat-Stamping Works
Heat-stamping (sometimes called debossing or hot stamping) uses a heated metal die to press the design into the leather. Instead of removing material, it compresses the leather fibers to create an indentation.
The process starts with a custom brass stamp. We mill these in-house based on your logo—a precision-cut metal die that captures every detail of your design. The stamp is heated to a specific temperature, typically between 300°F and 400°F depending on the leather thickness and design complexity.
Once the stamp reaches the right temperature, it's pressed firmly into the leather with consistent pressure. The heat and pressure work together to compress the fibers, creating a permanent impression.
Why Heat-Stamping Produces Better Results
Depth and texture. Heat-stamping creates a true three-dimensional effect. The design is pressed into the leather, not burned onto it. You can feel the impression with your fingertips. It has substance.
No burning or scorching. Because the leather isn't being vaporized, there's no risk of scorched edges or discolouration. The natural colour and texture of the leather stay intact.
Superior durability. Compressed leather fibers are actually stronger than the surrounding material. The impression won't fade, peel, or wear away with use. In fact, heat-stamped leather often looks better over time as the patch develops a natural patina.
Better aging. Full-grain leather that's been heat-stamped ages beautifully. The compressed areas take on a slightly different tone as the leather wears in, adding character rather than showing wear.
Cleaner lines. A well-made brass die produces crisp, consistent impressions every time. The edges are sharp and defined without the roughness that can come from laser burning.
The main trade-off is time. Heat-stamping requires creating a custom brass die for each logo, which adds a step to the process. It's also more hands-on than running patches through an automated laser machine. But we think the results are worth it.
Side-by-Side Comparison
| Factor | Heat-Stamping | Laser Engraving |
|---|---|---|
| Method | Compresses leather with heated brass die | Burns away surface with laser beam |
| Depth | Deep, three-dimensional impression | Shallow surface etching |
| Texture | Tactile, can feel the design | Flat, smooth surface |
| Durability | Excellent—won't fade or wear away | Moderate—can fade with heavy use |
| Edge quality | Clean, crisp lines | Can appear burned or rough |
| Aging | Develops character over time | May become less visible |
| Setup | Requires custom brass die | Digital file only |
| Speed | Slower, more hands-on | Faster, more automated |
| Cost | Higher upfront (die creation) | Lower per-unit cost at scale |
Why We Use Heat-Stamping
When we started Byward Outfitters, we tested both methods. The difference in quality was obvious.
Laser-engraved patches looked fine in photos. But in person, they felt flat. The burned edges were visible up close. And after a few months of wear on test hats, the designs started to fade.
Heat-stamped patches were different. They had weight to them. The impressions were deep and defined. And the more we wore them, the better they looked.
For us, the choice was clear. We're a small operation, and we're not trying to compete on volume or price. We're trying to make the best custom leather patch hats we can. That means heat-stamping.
Yes, it takes longer. Yes, it costs more to create the brass dies. But our customers aren't ordering hats to throw in a drawer. They're ordering hats to represent their business, their team, their brand. Those hats should look good on day one—and on day one thousand.
What About Cost?
Heat-stamping does have higher upfront costs because of the brass die. Each die is custom-made for your logo, which takes time and materials.
But here's the thing: we keep your die on file. Once it's made, you can reorder without paying for it again. The first order absorbs the setup cost. Future orders are faster and more cost-effective.
If you're planning to order hats once and never again, laser engraving might save you a few dollars per patch. But if you're building a brand and expect to reorder—or if you just want patches that last—heat-stamping is the better investment.
Choosing the Right Method for Your Needs
We obviously have a bias here. We use heat-stamping exclusively, and we think it's the right choice for anyone who cares about quality.
But we also understand that different situations call for different solutions. If you're ordering thousands of patches for a one-time promotional giveaway and cost is the primary factor, laser engraving might make sense. Just go in with realistic expectations about how those patches will look and hold up over time.
For custom hats that represent your business—merchandise you're selling, uniforms for your team, gifts for loyal customers—we'd recommend heat-stamping every time. The difference in quality is real, and it's visible.
See the Difference Yourself
If you're still on the fence, the best way to decide is to see both methods in person. Compare a heat-stamped patch to a laser-engraved one. Feel the difference. Look at the edges. Notice the depth.
Or just order a small batch from us and see for yourself. With a 5-hat minimum and a free mock-up option, there's not much risk in trying. We're confident you'll notice the difference.