Custom ball caps and flat-visor hats are popular gift items for a variety of occasions, and having an Epilog Laser machine allows you to personalize these items at the touch of a button! This sample club project covers laser engraving leather hat patches, as well as engraving and cutting custom wood veneer visor covers for caps. Read on to learn where we got the materials, laser parameters, and more! The best part? No sewing or stitching involved - watch the video above and see how we did it!

Supplies

We used a Fusion M2 40 120w:
Leather Patch Engrave: Raster // Speed 100% // Power 75% // 300dpi

Leather Patch Cut: Vector // Speed 80% // Power 100% // 50F

Hat Bill Engrave: Raster // Speed 100% // Power 30% // 600dpi

Hat Bill Cut: Vector // Speed 50% // Power 60% // 20F

Step 1: Prepare Artwork

Download the graphics here and import it into your graphic software. Make adjustments as necessary.

Step 2: Send to the Laser

Send the job to the laser with the correct parameters for your machine wattage. We recommend using the bottom-up laser engraving feature to avoid excess smoke/residue settling into the engraved portions of your design.

Step 3: Assembly

When laser engraved, leather can produce more smoke/residue than other substrates, so we recommend lightly wiping off the patches with a damp cloth when you're done to remove any residue left behind.

Lastly, remove the protective backing from the patch and brim and adhere them to your caps.