Custom leather patch hats for your business, team, or event

About our custom hats

• What type of leather do you use for custom patches?

  We use full-grain leather—the highest quality leather available. Full-grain means the hide's natural surface hasn't been sanded or buffed, so it's stronger, more durable, and develops a natural patina over time. It's the same leather used in premium wallets and belts, and it's why our patches look better the longer you wear them.

• Why are your patches heat-stamped instead of laser-engraved?

  We use heated brass dies to press your logo into full-grain leather, creating a deep, detailed impression with natural texture. Unlike laser engraving—which burns the surface and can look flat or scorched—heat-stamping produces a rich, premium look that won't fade or wear away over time. It's the same technique used by traditional leather craftsmen, and it's why our patches stand out.

• What leather patch shapes are available?

  We offer over 10 patch shapes including circle, square, rectangle, oval, diamond, and crest. You can choose your patch shape in our online customizer, or we can recommend one based on your logo. Different shapes work better for different logo styles—we're happy to help you pick.

• What hat styles are available for custom orders?

  We offer five hat styles: trucker hats, 5-panel hats, dad hats, flat brim hats, and jockey hats. Each style comes in a range of colours—over 50 across the lineup. Not sure which style is right for you? Reach out and we're happy to help.

• Where are your custom leather patch hats made?

  Our leather patches are handcrafted in our Ottawa, Canada workshop—we cut the leather, mill the brass stamps, and heat-stamp each patch ourselves. The hat blanks are sourced from trusted suppliers with ethically run factories in Asia, then assembled with our patches here in Ottawa. When you order from Byward Outfitters, you're supporting Canadian craftsmanship.

• How does the custom hat design process work?

  You have two options. You can use our online customizer to choose your hat style, select a patch shape, upload your logo, and preview your design in real-time. Or, if you'd prefer guidance, send us your logo and we'll create a custom mock-up within 48 hours—no obligation. Once you approve the design and place your order, we handle the rest.

• What file format do you need for my logo?

  We accept PNG, JPG, AI, EPS, PDF or HEIC files. High-contrast, black-and-white artwork works best for heat-stamping. If your logo has fine details or gradients, we may suggest simplifying it to ensure a clean impression. Not sure if your file will work? Send it over and we'll take a look.

• Can you design a logo for me?

  We're not able to create logos from scratch, but we can help prepare your existing logo for heat-stamping. If you have a rough idea or draft, send it over and we'll let you know if any adjustments are needed to ensure it stamps cleanly onto leather.

• What's the minimum order for custom hats?

  Our minimum order is just 5 hats. We're a small business too, so we wanted to make custom leather patch hats accessible for other small businesses, teams, clubs, wedding parties, and events—not just companies ordering hundreds at a time.

• How much do custom leather patch hats cost?

  Pricing starts at $40 per hat for orders of 5-9 hats and decreases with quantity—down to $18 per hat for orders of 200 or more. There's no setup fee, and the price includes your custom brass stamp, full-grain leather patch, and heat-stamping. Jockey hats are $1 more per hat at each tier.

• Do you offer bulk discounts on custom hats?

  Yes—the more you order, the lower the price per hat. Orders of 200+ hats are just $18 each, compared to $40 each for smaller orders of 5-9. There's no setup fee at any quantity.

• What happens after I place my order?

  Once your order is placed, we review your logo to ensure it will stamp cleanly. Then we craft a custom brass die of your design using traditional milling techniques. Your full-grain leather patches are heat-stamped by hand, attached to your selected hats, and quality checked before shipping. You'll receive tracking information once your order is on its way.

• How long does it take to receive custom hats?

  Most custom hat orders ship within 2-3 weeks from the date you place your order. This includes time to review your design, craft your custom brass stamp, heat-stamp your leather patches, and complete a quality check before shipping. Need them faster? Reach out—rush timing depends on order size and our current production schedule.

• Can I reorder custom hats later?

  Yes. We keep your custom brass stamp on file, so reorders are faster and easier. Just reach out or place a new order through the customizer using the same logo.

• What is your return policy for custom hats?

  Because each custom order is made uniquely for you, we're not able to accept returns once production begins. However, we review every design before we start and will reach out if we spot any issues. We're committed to making sure you're happy with the final product.

• What does your lifetime craftsmanship guarantee cover?

  We stand behind the quality of our work. If your leather patch peels, cracks, or separates from the hat due to a craftsmanship defect, we'll replace it—no time limit. This doesn't cover normal wear and tear, but it does mean you can trust that your hats are built to last.