Crafting Connection: How Custom Patch Hats Stitched a Brand into a Movement
Custom Patch Hats, headquartered in Raleigh, NC, has emerged as a market leader in crafting high-quality custom hats and apparel. The company, which has produced more than 4 million hats and served 30,000 customers across 50 states and 32 countries, prides itself on its commitment to local craftsmanship and international presence.
Custom Patch Hats began with two friends, a bartender and a landscape architect, who envisioned a business that would strengthen their community and state. Their dream has blossomed into a thriving enterprise, exemplifying “What’s made in North Carolina makes North Carolina.”
The company’s growth has been explosive over the past six years. In 2022, Custom Patch Hats was recognized as the 140th fastest-growing privately held company in the United States.
This rapid expansion has presented both challenges and opportunities for creative problem-solving. As co-founder Scott Alexander reflects, “We’ve had a lot of experience just throwing people at problems, and it’s nice to finally get to a point here in the business where we can solve them creatively and not because we have to.”
The company’s ability to adapt and pivot has been crucial to its success. Initially targeting the hospitality and event industries, Custom Patch Hats discovered that their core customer base lies in the construction and blue-collar outdoor sectors. This has driven their emphasis on durability and quality, aligning their products with the needs of these industries.
Custom Patch Hats is committed to environmental sustainability and community involvement. The company has planted more than 15,000 trees to support ecosystems and reduce its carbon footprint. Additionally, their collaborations with organizations like Activate Good and Habitat for Humanity mobilize community volunteering and drive positive change.
Custom Patch Hats has also created over 70 jobs in the manufacturing sector in North Carolina. The team fosters a close-knit, supportive environment where employees often socialize and enjoy each other’s company outside of work.
One of the key differentiators for Custom Patch Hats is their unwavering commitment to quality. Each hat undergoes meticulous inspection by hand, ensuring that the final product meets the highest standards. This dedication to excellence is echoed in the company’s core values: Human Connection, Innovation, Authenticity, Accountability, and Intent.
Custom Patch Hats offers a diverse range of customizations, including leather, PVC, woven, embroidered, and sublimated patches; direct embroidery; and thermoplastic polyurethane and silicone appliques.
Flynn Gniadek, a graphic designer at the company, says the process is about bringing ideas to life, “At Custom Patch Hats, we bring someone’s brand, or any kind of vision they have with a logo or art, to life. We put it on merch, whether it’s hats, apparel, or tote bag.”
Custom Patch Hats fosters a dynamic and supportive work environment by promoting employees from within and encouraging cross-training. This approach empowers employees to grow and take on new roles, reflecting the company’s collaborative and inclusive culture.
Jill Carlisle, who now serves as production manager, has seen her career rise since she started at Custom Patch Hats. “I actually started as a stitcher, then I was a production coordinator, and then I moved up to production manager. It’s really a great environment. I like to call it my second family.”
The production coordinators play a vital role in ensuring that each order is meticulously organized and meets the company’s quality standards. The final line of defense—the quality control team—works closely with stitchers to catch even the smallest flaws. Together, they ensure that every product is something the team is proud to stand behind.
Scott and fellow co-founder Brian Cox have created an environment where everyone has a voice. “One of Brian and I’s strengths has always been that we never want to be right. We just want things to be right, so we’re not afraid to experiment or try something new,” says Scott.
The future of Custom Patch Hats is bright. With plans to expand their product offerings and explore new markets, the company is poised for continued growth. “More product, more apparel, putting a lot more in someone’s shopping cart when they come and visit us,” said Scott. “We want to be everything that everyone wears.”
The passionate and dedicated team at Custom Patch Hats is committed to fueling human connection through branded apparel. Their innovative approach, coupled with their deep-rooted values and community focus, sets them apart in the industry.
As Flynn reflects, “It’s really amazing to see something you work on come to life. There is something magical about putting in hard work to help someone create cool merch.”
Custom Patch Hats is more than just a business; it is a testament to the power of vision, hard work, and community spirit. The company’s journey from humble beginnings to industry leader serves as an inspiration for anyone striving to make a positive impact in their community and beyond.