Custom Hats Wilmington, NC
The Merch Lab makes custom patch hats in Wilmington, NC, with woven and leather patches, from small runs to big orders.
Bring a logo or an idea. We will help you pick the patch, the hat and the finish.
Patch styles
Pick your finish
Four patch styles, pressed or stitched onto your hats.
Woven Patches
Fine detail and sharp small text, woven with a stitched border.
Embroidered Patches
Raised thread for a classic, textured stitched look.
Lasered Leather Patches
Laser engraved leather for a rugged, premium finish.
Raised PVC Patches
A raised logo with a soft rubber feel and a 3D pop.
Prefer your logo stitched straight onto the hat? See Custom Embroidery, for orders of 24 hats and up.
How it works
How hat orders work
1
Send your idea or logo
Send your logo, a sketch or an idea, and tell us the hat style and how many you need.
2
We quote your order
We look at your logo, patch and hat choice, then send you a quote before anything is made.
3
We make it
Your patches are pressed onto the hats.
4
Your order is ready
We let you know as soon as your hats are done, so you can get them to your team.
The process
How we make it
Pick your patch
Woven, embroidered, PVC (raised rubber), printed, or laser engraved leather, shaped around your logo.
Pressed on
Each patch is pressed onto the hat with heat and pressure for a clean, lasting finish.
Stitched on
Patches can also be stitched onto the hat. Tell us which you prefer when you ask for a quote.
Checked and ready
Every hat is checked before your order is ready.
Recent projects
Hat work
Woven patch, PVC patch and leather patch hats for brands, businesses and teams. Woven patches give a crisp, detailed logo. Leather patches give a rugged, premium look. PVC patches are a 3D mold of your logo with a top-tier design aesthetic.
Small runs and big orders
A handful of hats for a new brand or event, or a full order for the whole crew. Patch hats work for both, and every hat in the order gets the same clean, even press, or we can stitch your patch on for a premium price.
Reviews
“Jeff has handled our company’s clothing for the last couple of years, and his work is so reliable that we refuse to use any other vendor.”
Aris C., Google review
FAQs
Hat questions
Where can I get custom hats made in Wilmington, NC?
The Merch Lab makes custom patch hats and leather patch hats in Wilmington, NC. You can order online, by phone, by email or by appointment.
How do I customize a hat with my logo?
Send us your logo and tell us the hat style and how many you need. We help you pick the patch and the finish, then send a quote before anything is made.
Can I use my own logo?
Yes. Send us your logo or idea and we’ll quote it and make it.
What kinds of hats can you do?
We offer woven patch hats, leather patch hats, PVC rubberized patch hats, printed patch hats, and embroidered patch hats. Patches can be applied onto trucker hats and caps. We also offer embroidered hats for orders of 24 hats and up.
Do you take small orders?
Yes. Patch hats and leather patch hats work for small runs and big orders. Embroidered hats are for orders of 24 hats and up.
How do I order?
Online, by phone at 310-903-1212, by email at sales@themerchlab.co or by appointment.
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