Contract Hat Patch Sewing: Costs and Margins for Screen Printers
Michael Thompson · Decorators United
Published October 1, 2026
Build a real landed-cost estimate before quoting patch hats. Sewing is one line item, not the whole job.
Contract hat patch sewing lets a screen-printing shop sell decorated headwear without adding another production department. You source the blanks and patches, set the retail price and manage the customer. A sewing partner applies the patches to your specification. Decorators United provides this white-label service from Spokane, Washington, for screen printers and embroidery shops nationwide.
What does contract patch sewing cost?
Decorators United sewing starts at $3.00 per unit, with no order minimum or setup fee. Complex patches require a one-off quote, and recurring accounts can ask about volume pricing. This is a starting sewing price, not an all-inclusive decorated-hat price. Blank hats, patch production, freight and your shop’s overhead must be budgeted separately.
Calculate the landed cost before your margin
Use this worksheet: blank cost + patch cost + sewing cost + inbound freight per hat + outbound freight per hat + handling and expected spoilage allowance. Then compare that total with your selling price. Gross margin percentage equals (selling price minus landed cost) divided by selling price, multiplied by 100. Gross margin is not net profit: sales time, rent, software and other operating expenses still matter.
For illustration only, a $25 selling price and $12 landed cost leave $13 per hat before operating expenses, or 52% gross margin. Those numbers are hypothetical, not a supplier quote or a promised result. Run the same calculation using the actual hat model, patch dimensions and shipping destination for your order. Small runs are especially sensitive to freight because the same carton cost is spread across fewer units.
Quote the job, not just the stitch
Send the cap brand and model, patch material, patch dimensions, quantity, artwork mockup, placement and requested in-hand date. Flag multiple placements, unusual shapes and thick materials before approving a customer price. Include both shipping legs in your calendar. Decorators United offers a five-day standard production turnaround; confirm the production start and shipping schedule for your specific order before promising delivery. Rush production is available to discuss, not something to assume.
Protect recurring work with a repeatable specification
Keep the approved mockup, thread color, placement measurement and customer sign-off with the job. Photo proofing before production and QC photos before shipping create a useful record. For repeat accounts, save the exact bill of materials rather than rebuilding the quote from memory. A predictable workflow gives your sales team a headwear offer they can explain without becoming sewing technicians.
Quick answers for print shops
Is there a minimum order?
Decorators United has no minimum per order. Ask for a landed-cost estimate anyway: shipping can have a larger per-unit effect on smaller runs.
Can the finished hats go directly to my customer?
Yes. Blind shipping is available under your return address. Confirm packing instructions and the approved return address before production.
Get a usable price, not a guess
Send the hat model, patch type, quantity and turnaround through the quote form. We respond within 24 hours with pricing. Complex patches need a one-off quote. You print it. We sew it. Your customer stays yours.