— leather · vinyl · acrylic · uv & laser
Design custom hat patches your customers actually buy.
Upload art, auto-trace clean cut lines, pick your material, and mock it up on a real hat — then export print-and-cut files in minutes. No Illustrator degree required.
alone: $12/mo · $120/yr · $199 lifetime · in the pass: included
Auto cut lines & contours
SVG tracing and one-click contour offset turn any logo into a clean, cuttable outline you can trust.
UV printed or laser engraved
Switch methods on the same design — full-color UV on any patch material, or tonal engraving into 170+ two-tone leatherettes and woods, each with live per-inch pricing built in.
Live hat mockups
Your patch on 800+ real hat colorways — front and back views — so the design decision is made before a single sheet is printed.
Gang sheets + registration marks
Pack multiple patches onto one sheet with registration marks made for print-and-cut workflows — everything lines up on the first pass.
In-browser background remover
Knock out the background from a customer photo or logo without leaving the builder — no round-trip to another app.
Send-to-client proofs
Share a clean proof link so customers approve the exact patch before it goes into production. No more “wait, I pictured it bigger.”
Production-ready export
Print-ready sheets plus cut files including DXF — the formats your laser and cutter already speak.
Real dimensions
Design at true size with accurate measurements, so what leaves the machine is what you drew.
— the old way
- · Redraw cut lines by hand in complex software
- · Bounce between four different apps
- · Guess how it will look on the hat
- · Email a flat JPEG and hope
- · Wrestle files into the right format
— with patchforge
- · Auto-traced cut lines and contours in one click
- · Art, materials, mockup, and export in one place
- · Live hat mockups before you print anything
- · Shareable proof links customers approve
- · Print-ready sheets + DXF cut files, done
— from the shop floor
“We run a hat bar at weekend markets — customer picks a blank, picks a design, and I mock the patch on their exact hat while they watch. Add-on patch sales roughly doubled the first month.”
“The cut file just runs. I export for my laser, drop it in, and the cut follows the patch exactly — no re-tracing, no test cuts, no scrap pile of leatherette.”
“Listing photos used to mean a whole afternoon with a camera. Now I mock one design across a dozen hat colors and my Etsy listings are up the same day.”
“Gang sheets with registration marks made print-and-cut boring — in the best way. We batch a full sheet of patches and everything lines up on the first pass.”
“I send the proof link, the customer taps approve on their phone, and production starts. No more “wait, I pictured it bigger” after the patch is already cut.”
“I replaced Illustrator, Photoshop, and two plugins with one browser tab. My part-timer learned the whole flow in an afternoon — that alone paid for the year.”
Making a patch shouldn’t take longer than making the sale. PatchForge replaces the four-app juggle with one browser tab — and in the FoundryPass it comes with the rest of the workshop.
Alone it’s $12/mo. In the pass, it’s one of four.
See FoundryPass pricing