Garment Decoration Service

We are here to help with custom hats and apparel. We can put your brand name, brand image or company logo on our garments. Decorate a garment for your events or social gathering.

You can choose from a large collection of blank garments we have in stock and carry – but we can also source any kind of hat or apparel you are looking for.

Your design can be placed with various methods on to your hat or shirt. Here are some of the popular methods of decorating your garments:

 

DTF Heat-Transfer

DTF (Direct-to-Film) transfers work by printing a design onto a special film, coating it with a powdered adhesive, and then using a heat press to transfer the design onto fabric. The process involves a digital print with special DTF inks, a curing stage to melt the powder, and a final heat press application that melts the powder and bonds the ink to the garment.

DTF works on virtually all fabrics and colors (including cotton and dark materials), while dye-sublimation is limited to white or light-colored materials and for polyester garment materials, or poly-coated items.

DTF is the best method any kind of hat or shirt (polyester or not), it is versatile, allowing for vibrant, full-color designs on a wide range of fabrics and colors (even dark colored garment) without the need for any pre-treatment.

 

Embroidery on any garment

Embroidery is decorating a garment with needle and thread to create designs, logos, or patterns. This is done with an embroidery machine, and the process can be applied to almost any clothing item, including shirts, hats, and jackets.

 

3D-Puff embroidery

3D-Puff embroidery is a technique that creates a raised, three-dimensional design by placing a foam underlay beneath the embroidery stitches. The foam is cut to the shape of the design, and the machine stitches over it, lifting the design off the fabric to make it "pop". This method is frequently used for bold logos, lettering, and designs on items like hats, jackets, and bags.

 

Silkscreen on shirts

Silkscreen is a printing method where ink is pressed through a mesh stencil to transfer your design onto a t-shirt. The frame has mesh stretched over it, on which emulsion, is a light-sensitive liquid, is coated onto the screen to create a stencil. It works by hardening when exposed to UV light, while areas blocked by a film positive remain soft and can be washed away. This process creates a stencil on the screen mesh that acts as a barrier, allowing ink to pass through only in the desired image areas for printing.

For multi-color you must use a frame for each color, and align each color screen perfectly to the last. Then print one color at a time, and ensure each layer is at least partially dry before adding the next. Key steps include creating separate screens for each color, using registration marks for alignment, printing the base or lightest color first, and using a flash dryer to dry the ink between color changes.

This process creates high-quality, durable prints and is ideal for creating custom shirts, especially for large orders.

 

Patch, Emblems and Labels

At Gear Direct LLC we can make custom patches for your hat or uniforms. The patch become part of your clothing and it makes them look professional. We are your source for all your patches and embroidered-related products. Our patches are created with the highest quality materials and threads to ensure the products is durable, keeps its colors after multiple washes and daily wear. Every patch is made to your specifications and material requirements.

Here are some of the most requested patch types..
– this list is not complete as there are so many patch types:

 

 

Molded Silicone Patch

It is a modern and innovative solution for branding and decorative embellishments. It is made from premium-grade silicone which makes them an ideal choice for applications requiring resilience and a standout appearance.

They are heavy-duty in the sense that they are resistant to wear and tear, and they can withstand extreme weather conditions, maintaining their look and feel over time. They are waterproof and gives your patch a modern professional look.

 

Tatami Fabric Silicone Patch

Add white tatami fabric as backing cloth for your silicon patch. It provides a unique texture in the background. The highlight of the sleek patch is the slightly raised, tactile feel.

 

TPU Patch

Crafted from Thermoplastic Polyurethane, TPU patches are engineered to withstand the most challenging conditions while maintaining its striking colors. Our technology allows to bring your artwork to life with exceptional clarity and detail. It lets you can create eye-catching TPU patches that stand out on any garment or accessory.

 

Soft PVC Patch

Made from high-quality, flexible soft PVC. The soft PVC patch is perfect for those who need something more rugged and long-lasting. They can be made with bold, 3D-like designs. Our PVC patches add a professional and stylish touch to any item, from hats, uniforms, bags and jackets.

 

100% Embroidered

Embroidered patches are made by stitching thicker colored threads into a twill backing. This method has been used for decades, giving patches a traditional, handcrafted look.
Using only the finest quality materials and embroidery threads. We create your patches with three goals in mind: to represent your organization well, to provide long lifespan and to enhance the appearance of the clothing they are sewn to.

All embroidered patches are made with:

• The use of computerized machinery for exact precision
• Fade-resistant, polyester color threads (you receive up to 7 at no additional cost!)
• A high-thread count, fine-twill backing for long-lasting quality
• 100% machine washable, dry-clean safe materials

 

Partially Embroidered

Partially embroidered is put on a background base. The background cloth will be showing at the parts that are not embroidered. The less stitching on the emblem makes it cheaper than the fully embroidered patch. The blank background is part of the design.

The inner circle is shown the background on this patch design. But it has the US Flag printed in the middle. Which was done with a process called sublimation. A sublimation transfer of a digital image (in this case the US Flag) was printed with a specialized sublimation printer and then the transfer was put onto center textile fabrics with a heat press.

 

Woven

Woven patches have a smooth, flat surface, making them ideal for detailed designs with smaller text, while embroidered patches have a raised, textured, and three-dimensional appearance from thick threads stitched onto a fabric background. The key difference is the construction: woven patches interlace fine threads like fabric on a loom, whereas embroidered patches stitch thread on top of an existing base.
Woven patches = detail and precision. Embroidered patches = texture and tradition.
Both offer high-quality ways to showcase your brand, club, or organization.

 

Dye Sublimated

A dye-sublimated patch makes it easier for your patch to have fine details and a full colors.
The main difference is that sublimated patches are printed with full-color, high-detail, and photo-realistic designs, while embroidered patches are stitched with thread, giving them a raised, textured, and more traditional look.
Sublimation allows for a smooth, flat finish and unlimited colors, making it ideal for complex graphics, while embroidery is best for simpler design.
The sublimation ink permeates the fibers of the fabric and are locked in place, providing a colorfast fabric that is in many ways a photo-realistic recreation of the original image.
This innovative and revolutionary technology paves the way for us to help you unlock bold and vivid new promotional products for your brand or company.

Sublimation over a twill fabric background

Sublimation patch over a 100% stitched background

Putting a sublimation patch over a 100% stitched background, combines the full-color detail of sublimation with the texture and dimension of embroidery. This creates a unique hybrid patch that showcases detailed, photographic images on the flat, sublimated base while adding embroidered elements like borders or highlights to provide a 3D, textured effect that a purely sublimated patch on twill would lack.

 

Chenille

Chenille high-loop embroidered emblems have that classic wool-like texture and feel. Chenille patches are decorative patches made from a thick, fuzzy yarn that is embroidered onto a soft, towel-like material, often with a felt background. They are known for their plush texture and have a classic, vintage look, often used for personalization on varsity jackets, hats, and hoodies.
Chenille patches are associated most with letterman jackets, but chenille (French for caterpillar) applications range far and wide.
Chenille emblems are great not just for jackets, and are both visually distinct as well as remarkable in how they feel.

 

Leather

A leather patch is a great choice of decoration. The piece of leather can be laser-etched with your design, or even debossed.
Debossed leather patches have your design or pattern pressed down into the material, creating a recessed or sunken impression. The process is done with a metal die, heat, and pressure to imprint onto the surface of the leather, resulting in a subtle, long-lasting mark. This technique is a popular way to personalize leather patches.
These patches are popular for their rustic and premium appearance and can be made from real or faux leather.

Backing Types

• No backing: only for sewing on the fabric
• Ironed-on: heat seal iron-on backing
• PVC Backing: Standard patch backing used for stabilization and sew-on purposes
• Hook-and-Loop: Velcro hook and/or loop backing available.
• Felt Backing: Soft felt backing.