How We Make the Leather Patch on Every Outer Wings Hat
Every Outer Wings hat starts with a story — and most of the time, that story begins on the trail. Whether it’s a sketch pulled from a sunrise hike or a logo reimagined for a small business, our leather patches go through a deliberate, hands-on process before they land on your head.
Here’s a behind-the-scenes look at how we make each patch — both for our original designs and for custom orders — from idea to final stitch.
The Design Process: From Sketchpad to Snapback
For Pre-Designed Outer Wings Hats
A new patch idea often starts on the mountain, sometimes literally. Maybe it's a photo from a recent hike in the Rockies or a view from a powder day in Breckenridge. That visual becomes inspiration for a concept, which starts as a pencil sketch. Usually not just one sketch, but three… maybe four… maybe more.
Once we’ve got a few strong concepts:
- We digitize them into clean, vector artwork (essential for leather engraving)
- We test different patch shapes and sizes on-screen
- Then we either render the patches digitally or physically laser-engrave samples
- We pin each option on a range of hat styles to see what actually looks best
Sometimes a design looks amazing on paper but just doesn’t translate to a flat bill rope hat or pops perfectly on a low profile trucker. That’s why we go through multiple rounds of testing and refinement.
Final designs go through an internal (and sometimes external) voting process, and once the winner is clear, we photograph the hat and create the final product listing.
👉 Check out the Mountain Hats Collection…
For Custom Leather Patch Hats
Our custom leather patch hat process follows many of the same steps — with one big difference: it’s all about getting the design exactly right for your brand, team, or shop.
Here’s what it looks like:
- You send us your logo (ideally as a vector file like .AI, .EPS, .PDF, or .SVG)
- If you don’t have a vector file, we’ll recreate your artwork in vector format
- We explore the best patch shapes for your logo — some are obvious, others need trial and error
- You’ll get multiple options to choose from — not just one
- Different leather colors
- Stitching options
- Patch shapes and sizes
- Rendered mockups on the hats of your choice
We send you high-quality digital mockups so you can visualize exactly what your hats will look like before we ever cut leather or stitch anything.
Once approved, your order moves into production. No surprises. No pressure. Design work is free, and we never produce a hat without your green light.
👉 Browse our Trucker Hats Collection…
The Patch-Making Process (After Design)
Once the design is locked in — whether it’s one of ours or yours — we move into leatherwork:
1. Real Leather Only
We use full-grain, vegetable-tanned leather for every patch. This gives it a premium look, natural wear, and a high level of durability.
2. Laser Engraving
We engrave the design directly into the leather using a precision laser. This isn’t printing or stamping — it’s a permanent mark, burned into the grain.
3. Sealing and Finishing
After engraving, we lightly brush the patch, then apply a sealant to protect it from water, sun, and wear — without making it shiny or fake-looking.
4. Sewn by Hand — Always
Each patch is sewn directly onto the hat. No glue. No shortcuts. Just heavy-duty thread and attention to detail.
👉 Explore the Low Profile Hat Collection…
Featured Hats That Showcase the Full Process
1. American Flag Hat – Richardson 115
Our bestselling low profile hat with a timeless 1776 flag patch. Simple, rugged, and stitched to last.
- Breathable mesh back
- Low crown fit
- Hand-sewn veg-tanned leather patch
👉 Check out the Patriotic Hats Collection…
2. Mountain West – Richardson 256
A classic rope hat snapback for people who love the backcountry. Flat bill, soft-structured, and loaded with quiet character.
- Cotton/nylon blend with UPF 50+
- Real leather patch with mountain silhouette
👉 Browse more Rope Hats…
3. Lost Pine – Richardson 115
A customer favorite for everyday wear, hiking, or working outside. Compass and pine design engraved and sewn on by hand.
- Available in M/L and Small sizes
- Leather patch laser-engraved in Colorado
👉 Explore the Low Profile Trucker Hat Collection…
Wherever You Wear It, the Craft Shows
Whether you're grabbing coffee in a mountain town, biking the trails in Western North Carolina, or running a construction crew in Colorado — the difference is in the details. That’s why we obsess over every patch we make.
Want to explore more styles?
Common Hat Questions
Are all Outer Wings patches made of real leather?
Yes. Every patch is full-grain, veg-tanned leather — engraved and sewn by hand in Breckenridge, CO.
Can I submit my own design?
Absolutely. We’ll work with your logo and send digital mockups with multiple options — shapes, colors, and thread styles.
Do you glue your patches?
Never. Every patch is sewn, which is why they last so long and look so good.
Is the design process free?
Yes. We don’t charge for design mockups or revisions — and we won’t make your hats until you approve the final design.
From Sketch to Stitch — We Do It Right
Whether you're grabbing a pre-designed favorite or building out a custom order for your team, Outer Wings hats always start the same way: with real materials, real design, and a hands-on process that never cuts corners.
