Table of Contents
Watch the video: DIY Sublimation Hat Patches: Make Your Own Raggy Hat Patches by The Sarcastic Crafter
If you’ve seen those fray-edged “raggy” patches popping up on hats everywhere, you know the look: rustic, colorful, and undeniably custom. This tutorial walks you through the exact process shown in the video—from design setup through pressing, fraying, sealing, and finally mounting your patches on hats.
What you’ll learn
- The essential supplies for raggy sublimation patches (and why 100% polyester linen matters)
- How to set up, size, and print in design software, then press at 385°F for 60 seconds
- The simple techniques to fray edges and stop them with liquid sealant
- How to glue and align patches onto hats—and what to expect with sizing
Introduction to Sublimation Hat Patches Raggy hat patches take the precision of sublimation and add a soft, frayed edge that feels handmade in the best way. In the video, the creator prints multiple small designs, presses them all at once onto polyester linen, then cuts, frays, seals, and glues the patches to trucker-style caps.
What are Raggy Hat Patches? They’re sublimated fabric patches with intentionally frayed edges. The key is a fabric that both sublimates vibrantly and frays nicely—100% polyester linen does both. After sublimation, you trim a shape around each design, pull a few threads for that textured edge, and seal the fringe so it doesn’t keep unraveling.
Why DIY Sublimation Patches? You control the art, size, and fabric—and you get a boutique finish without a complicated setup. They’re ideal for small-batch personalization, seasonal drops, or one-off gifts. If you’re building a craft side hustle, the process is straightforward once you dial in your press settings. embroidery machine for beginners
Gathering Your Essential Tools & Materials Start with the must-haves the creator used on camera:
- Hats: Trucker style with mesh backs (the Adams brand appears in the video).
- 100% polyester linen fabric: Selected specifically because it sublimates bright and frays at the edges. The exact fabric name isn’t specified beyond being 100% polyester from a craft store.
- Adhesive: Aileen’s Fabric Fusion Permanent Fabric Adhesive to attach patches to hats.
- Fray sealer: Dritz Fray Check to stop the fray at just the right point.
- Sublimation paper: The creator later confirmed in comments that they used Asub 120 in this project.
- Heat press, scissors, lint roller, and optionally a weeding tool, seam ripper, or needle for fraying.
Pro tip Have butcher paper ready—one sheet under your fabric and another on top—to protect your press and keep everything clean during sublimation.
Watch out Using anything other than 100% polyester fabric may lead to dull transfers. The creator emphasizes polyester linen for a reason.
Designing & Printing Your Sublimation Patches Software Setup (Silhouette Studio) The creator uses Silhouette Studio because it’s familiar and free to use for printing. They import designs via File > Merge, arrange them, and size within a roughly 4 x 4 inch working area (no more than four inches tall).
Quick check Before you print, mirror your artwork. The creator verifies the designs are mirrored correctly on screen and paper—don’t skip this.
Sizing and Mirroring Your Designs If you’re after that oversized statement, 4 inches is bold. The creator notes they’d likely size some designs down slightly in future—around 3–3.5 inches—for a more subtle look on certain hats.
Printer Settings for Vibrant Transfers In the video, paper size in software is set to custom, matching 11 x 17 inches. The creator uses an Epson ET-15000 and selects a preset called “11 x 17 Adobe,” then prints. The exact color settings aren’t detailed here, but the result is crisp and richly colored.
Heat Pressing Your Designs onto Fabric Fabric Preparation: Pre-Press & Lint Roll Cut your fabric to fit your layout and pre-press briefly to flatten and remove moisture. Lint roll thoroughly—stray lint can bake in as small white flecks under your design.
Optimal Heat Press Settings (Temperature & Time) The creator presses at 385°F for 60 seconds on 100% polyester. They specifically choose 385°F (instead of 400°F) because polyester often doesn’t require the higher temperature, and the results at 385°F were very vibrant.
Layering for a Perfect Sublimation
- Butcher paper on the lower platen
- Fabric on top
- Lint roll again
- Sublimation paper face down, secured with heat-resistant tape on the corners
- Butcher paper on top
- Press: 385°F for 60 seconds with steady pressure
After pressing, they reveal a bright, clean transfer—no dullness, no scorching.
Pro tip Tape the corners to prevent ghosting. A secure stack resists any micro-shifts when the press opens. snap hoop monster
Creating the Iconic Raggy Edges Cutting Your Patches to Shape Trim each design with scissors, leaving a halo of fabric around the art. That extra space is what you’ll fray—don’t cut too close or you’ll lose the raggy edge. The creator opts for organic shapes, not just perfect circles or squares.
The Art of Fraying Use a weeding tool, seam ripper, or even a needle to gently pull a few threads from the edges. Work slowly around the perimeter and keep an eye on the artwork—stop if the fray gets too close to your design.
Sealing the Edges with Fray Check Once you love the look, apply Dritz Fray Check around the fringe to lock it in. It’s sealed at the fiber level so the look stays rustic without unraveling into the print. The bottle arrives sealed; puncture the tip as directed, then run a thin, consistent bead around the edges. Set the patches aside to dry. The label suggests 15–30 minutes; the creator waited about 20 minutes on a slightly warm press surface.
Watch out Handle carefully while wet—Fray Check can spread or stiffen areas you didn’t mean to treat if you smudge it.
Assembling Your Custom Hat Patches Applying Fabric Fusion Adhesive With frayed edges sealed and dry to the touch, flip a patch over on a protected surface. Apply Aileen’s Fabric Fusion generously and evenly across the back, concentrating on the edges so they don’t lift.
Securely Attaching Patches to Hats Align with the hat’s center seam if it has one, then press down firmly and work around the edges, smoothing out any gaps or bubbles. The creator notes that applying more adhesive at the edges helps them lie flush while setting.
Tips for a Smooth, Lasting Adhesion
- Press and hold each section a moment to help the glue bond evenly.
- If you see an edge lifting, lift gently, add a touch more adhesive, and press again.
- Let the hat sit while you work on others so the glue can begin to set.
From the comments Viewers asked how the glue holds up. The creator reported that a hat made for their household and worn often during outdoor work shows “no issues at all” so far. Long-term durability under repeated washing wasn’t tested in the video. fast frames embroidery
Pro tip If you prefer a sewn look, a commenter suggested using a tear-away paper stabilizer beneath and sewing around the design line. While the video focuses on glue, this idea can mimic a stitched-on finish.
Final Thoughts and Sizing Considerations Reviewing Your Finished Hats The results are vibrant and crisp, with that soft rustic fringe you want from a raggy patch. Right after gluing, you may notice darkened “wet” areas showing through the linen—this is normal and dries clear.
Choosing the Right Patch Size A 4-inch patch is a statement on a hat, and that’s what’s trending for some sellers. The creator personally prefers some designs closer to 3–3.5 inches for balance. They also try on a hat on camera so you can see how a 4-inch patch wears in real life.
Maintenance and Durability
- Adhesive: The creator mentions they’ll continue to monitor durability over time. Early feedback is positive.
- Washing: The video doesn’t test or specify machine washing. If your hats get washed frequently, consider spot-cleaning or testing a spare hat first.
Quick check Your patch should feel firmly bonded all around, especially the edges. If you spot any corner lifting after a few hours, add a touch of adhesive and press again.
Troubleshooting Notes From the Workshop
- Ghosting: A viewer asked if pressing a full sheet leads to ghosting. The video doesn’t provide a direct answer, but consistent taping and a stable stack are your best prevention.
- Color vibrancy: If your polyester is truly 100%, pressing at 385°F for 60 seconds—as in the video—can deliver vibrant results. Dullness often traces back to fabric composition or incorrect mirroring.
- Fabric ID: The creator mentions the polyester linen came from a craft store and is 100% polyester; the exact product name isn’t specified.
From the comments: favorites and feedback
- Favorites: Many loved “It’s Fall Y’all,” “Mama,” “Bee Kind,” and “Small Business Owner.”
- Size preferences: Several viewers agreed that 3–3.5 inches strikes a great balance while 4 inches makes a bold statement.
- Paper and printer: Asub 120 paper was confirmed by the creator in the comments; printing was done on an Epson ET-15000.
Optional add-ons for future builds
- Sew lines: If you’d like a stitched edge, consider adding a simple straight stitch just inside the fray (test on scraps first). This is not shown in the video but can give a classic workwear vibe.
- Design variations: Try lighter or darker shades of polyester linen. The creator used a light fabric so the prints pop.
- Production scaling: If you plan to produce sets, batch your steps: press multiple designs, then cut, fray, and seal in one session.
Watch out Don’t over-fray. Keep an eye on your artwork and stop once you’re happy with the texture—then seal quickly to lock it in.
Small-biz notes and practical takeaways
- Appeal: These hats are timely and highly customizable.
- Workflow: Keep butcher paper on hand and refresh if it gets ink transfer.
- Sizing library: Save 3 in, 3.5 in, and 4 in templates in your software for quick iterations.
From design desk to doorstep: your repeatable recipe 1) Arrange and mirror your art in Silhouette Studio or any software you prefer. 2) Print on 11 x 17 sublimation paper (Asub 120 was used in the video) with an Epson ET-15000 or similar. 3) Pre-press and lint roll 100% polyester linen. 4) Press at 385°F for 60 seconds with butcher paper layers and taped corners. 5) Cut shapes, fray carefully, then seal edges with Fray Check and let dry. 6) Glue evenly, align on the hat, and press edges down firmly until set.
A final nudge Whether you go bold at 4 inches or dial it back to 3–3.5 inches, this project shines because you pick the art, fabric, and finish. Build a small collection of seasonal designs, try a few colorways, and ask your customers—or your own closet—which ones stick.
Future-friendly embellishment idea If you ever want to add decorative stitching or patches later with a home embroidery setup, keep your hats flat and stabilized for best results. Makers who branch into embroidery sometimes explore accessories like magnetic embroidery hoops for easier hooping and alignment, but that’s an optional path beyond what’s shown here.
Last look Clean color, soft fray, sealed edge, and a firm bond to the hat—that’s the raggy patch formula. Tweak sizing to taste and you’ve got a repeatable, giftable, sellable staple.
From the comments: quick answers
- Sublimation paper used: Asub 120 (comment reply from the creator).
- Printer: Epson ET-15000 (shown and mentioned in the video).
- Software: Silhouette Studio; the creator notes other software like Photoshop can work too.
- Glue performance: Reported holding up well in real-world outdoor wear; long-term washing wasn’t covered in the video. mighty hoops
Tip for multi-project crafters When your workflow expands into mixed techniques (vinyl, sewing, or later embroidery embellishments), plan your workstation for easy swap-outs. Some crafters like modular tools such as magnetic hoops for embroidery for different fabric types, though that’s not required for these sublimation patches.