Table of Contents
Video reference: “Let's Make a Trendy Applique Dad Hat with Leatherette on a Laser!” by Kayla's Corner
These leatherette applique hats are everywhere—and for good reason. They’re quick to design, laser-friendly, and look polished on classic dad caps. This guide turns the full process into a tight, repeatable workflow—design in LightBurn, laser cut Lonestar Leatherette, clean, inlay fabric, and press onto a Richardson hat with a dual-heat platen.
What you’ll learn
- The exact LightBurn setup for a rounded rectangle “DAD” patch
- Laser cut parameters that work on leatherette (with air assist)
- How to size and place a fabric inlay so it fills letters cleanly
- Why a dual-heat hat press helps tack and align tiny inner pieces
- Practical fixes for soot cleanup and avoiding press marks
Primer: What this project achieves and when to use it A leatherette applique dad hat pairs a crisp, laser-cut outer patch with a fabric underlay that peeks through the letter cutouts. You’ll design and cut a rounded rectangle patch with “DAD” in Impact font, prepare a small fabric insert, and heat press everything to a Richardson cap. The result: a trendy, textured look with bold letter windows that let the fabric shine. embroidery machine for beginners
When to use it
- You want a fast, polished cap with bold lettering and a patterned pop.
- You like the leatherette look and want clean, repeatable results.
- You have access to a laser cutter and a hat press (dual-heat platen recommended).
Constraints to keep in mind
- Laser settings vary by machine and leatherette; expect to dial in for your material.
- A dual-heat platen simplifies alignment and pre-tacking; top-heat-only presses require more care or temporary securing.
- Soot cleanup is part of the process—plan a quick cleaning pass after cutting.
Prep: Materials, tools, and safety Materials
- Lonestar Leatherette (outer patch)
- A small piece of fabric (cotton, flannel, upcycled onesies all work)
- Richardson dad hat
- Masking tape (backing the leatherette aids handling and can reduce mess)
- LA Awesome cleaner (spray) and paper towels
- Silicone sheet (for pressing cover)
Tools
- LightBurn software
- Laser cutter
- Pencil and scissors (for the fabric inlay)
- Hat press (Hotronix Fusion IQ 360 dual-heat platen in this build)
- Lint roller
Safety notes
- Heat caution: The lower platen runs hot—handle carefully to avoid burns.
- Laser byproducts: Cleaning removes soot and residue; avoid smearing onto finished surfaces.
Quick check
- Design file ready in LightBurn
- Leatherette and fabric on hand
- Heat press warmed and clear workspace near the press
Prep checklist
- Leatherette backed with masking tape
- Fabric selected and prepped
- Cleaner, towels, silicone sheet, lint roller at the press
- Laser and press warmed and ready
Setup: Design choices and configurations Patch geometry
- Base shape: Rectangle, sized to 3.9 in (W) × 2.2 in (H)
- Rounded corners: 0.2 in for a smooth, pro edge; feel free to test 0.1 or 0.025 for a sharper look
Create the base rectangle In LightBurn, draw a rectangle and set width 3.9 in and height 2.2 in. Lock the dimensions if you want to maintain aspect while testing corner radii later.
Round the corners Select the rectangle, open Shape Properties, and set corner radius. A 0.2 in radius yields a soft, modern edge that eases weeding and improves comfort at the hat’s curve.
Add the letters Type DAD in Impact and size it so the letters fill the interior generously while keeping a clean frame all around the edges. Center the letters to the rectangle for perfect alignment.
Cut vs. engrave Ensure all layers are set to Line (cut), not Fill (engrave). For visual clarity, you can color the cut layer red if that’s your convention.
Why these choices matter
- Rounded corners reduce edge catching and look finished.
- Impact’s weight produces bold windows that spotlight the fabric.
- A generous border around the letters gives the adhesive enough leatherette-to-hat contact.
Setup checklist
- Patch rectangle: 3.9 × 2.2 in
- Corner radius set (0.2 in shown)
- DAD in Impact, centered
- Cut mode confirmed (Line), preview looks correct
Operation: Step-by-step build Step 1 — Laser cut the leatherette
- Back the leatherette with masking tape.
- Place in the laser and send the LightBurn file.
- A typical working setup in this build: 10 mm/s, 90% min power, 10% max power, air assist on. Monitor and adjust per your machine.
Expected outcome: A clean outer patch and crisp internal letter windows.
Watch out
- If you see excessive soot, you may need to test alternate speeds/power or additional passes. Backing with tape also helps retain debris.
Step 2 — Clean the leatherette
- Spray LA Awesome onto paper towels.
- Wipe both sides of the cut patch to remove soot and residue. Avoid saturating; work with fresh towels as they darken.
Expected outcome: Surfaces feel dry and clean to the touch, no loose debris.
Pro tip A commenter asked about minimizing press marks on the cap edges; the creator uses a protective cover and, in this build, places a silicone sheet over the patch before pressing. This helps shield the surface while delivering even heat.
Step 3 — Prepare the fabric inlay
- Place the leatherette over your fabric and trace the inner letter shapes.
- Cut the fabric slightly inside your trace so pieces nest within the letter openings without overlap.
Quick check Lay the leatherette back on top. Your fabric should disappear under the patch edges, with the pattern centered where you want it.
Community note One question asked whether to add fusible to the fabric. The creator did not apply additional fusible in this build and mentioned they might try it in the future.
Step 4 — Prep the hat on the press
- Seat the Richardson hat snugly on the platen.
- Lint-roll the press area so adhesive meets clean fibers.
Expected outcome: A centered, stable hat surface ready to accept the patch.
Step 5 — Align and pre-tack using dual heat
- Place your fabric pieces down where the letters will be.
- Lay the leatherette patch over, centered and straight.
- On a dual-heat platen, the warmed lower platen activates the adhesive lightly—use your fingers to press in place and secure those small inner letter pieces.
Why dual-heat helps The lower platen provides gentle pre-tack, so delicate centers (like the A’s inner piece) stay put before the full press. This minimizes shifting.
If you only have a top-heat press
- Use heat-safe tape sparingly to keep components from moving.
- A commenter proposed pre-assembling the stack on a release surface and transferring as one piece. This was not tested in the build—try cautiously on scraps first. brother hat hoop
Step 6 — Press to finish
- Cover with a silicone sheet for protection.
- Press on the Hotronix Fusion IQ 360 at about 320°F. Confirm the entire patch bonds and edges are secure.
Expected outcome: The leatherette adheres firmly, the fabric shows cleanly through the letters, and the patch sits straight.
Operation checklist
- Leatherette cut and cleaned
- Fabric trimmed slightly smaller than openings
- Hat clean and centered on the platen
- Patch aligned; inner pieces secured
- Covered with silicone sheet and pressed
Quality checks at each milestone Design check
- Rectangle is 3.9 × 2.2 in; corners are rounded to taste.
- DAD (Impact) is centered; preview shows only lines (no fills).
Cut check
- Edges cut through cleanly; small parts retained.
- Soot is present but manageable; backing tape contains debris.
Cleanliness check
- Leatherette surfaces wiped and dry; no residue transfers to fingers.
Fit check
- Fabric pieces sit fully within the letter windows; patterns appear where intended.
Press check
- Patch is centered and straight on the hat.
- After pressing, edges are flat with no lifting.
- If a tiny area needs extra adhesion, spot re-press with protection.
Results and handoff Deliverable
- A finished Richardson dad hat with a leatherette DAD patch and fabric inlay, securely bonded and aligned.
Care and sharing
- Allow the hat to cool fully before handling. Check edges once more and re-press if needed.
- Note any minor alignment learnings for the next run; the small inner “A” piece is often the hardest—pre-tack carefully.
Scaling ideas
- Swap fabrics for seasonal prints or keepsake materials (the creator notes cotton, flannel, or pieces from onesies/blankets can be used).
- Adjust letter sizing to leave room under the text for an extra engraved line if desired (e.g., names or dates in future variations).
Troubleshooting and recovery Symptom: Excess soot on the leatherette
- Likely cause: Settings too hot/slow; unoptimized airflow.
- Fix: Test different power/speed or multi-pass strategies. Keep air assist on. Continue backing with masking tape and clean promptly with LA Awesome.
Symptom: Inner letter pieces shift
- Likely cause: No pre-tack from the lower platen; movement while closing the press.
- Fix: Pre-tack on a dual-heat platen. On single-platen presses, use heat-safe tape and close the press carefully.
Symptom: Visible press marks on the cap sides
- Likely cause: Direct contact with hot platen and high pressure.
- Fix: Use a protective cover and ensure coverage over the patch. The silicone sheet in this build protects the surface.
Symptom: Patch edges lifting after cool-down
- Likely cause: Incomplete heat/pressure at edges.
- Fix: Spot re-press with a silicone sheet, focusing heat and pressure on the lifted area.
From the comments: Helpful community tips
- Adhesive under the fabric? The creator did not add extra fusible in this build and noted they might try it later.
- Which hat press? Hotronix Fusion IQ 360 dual-heat platen. The lower heat activates adhesive for accurate placement.
- Cover sheet to avoid marks? A protective cover was referenced; in this process, a silicone sheet was used over the patch before pressing.
- No lower heat? One commenter suggested pre-assembling on a release surface and transferring. This was not tested here—experiment cautiously.
Cross-craft note If you usually tackle caps with machine embroidery hardware, this leatherette method is a fast, no-stitch alternative for bold text graphics. hoop master embroidery hooping station
Planning future builds If you source or compare equipment across shops, you may see discussions around accessories and frames in the embroidery world—even though this method doesn’t require them. Consider how those workflows compare when deciding which technique suits a given design. magnetic embroidery hoops
Many readers come to leatherette patches from an embroidery background; it’s common to weigh which process fits the job, the timeline, and the look you want. brother embroidery machine
If you’re organizing a production table for mixed techniques (embroidery on some items, laser + press on others), keep your consumables clearly separated so residues don’t cross-contaminate delicate textiles. snap hoop monster
As you standardize templates, jot down your exact dimensions and letter sizing for quick repeats. This speeds orders during busy seasons when you’re also queuing other cap workflows. mighty hoop 5.5
Finally, if your shop’s cap process usually starts on embroidery fixtures, this leatherette route offers a different path to clean, graphic results—especially handy for thick, bold type. magnetic embroidery hoops for brother