A few days ago, I got a message from a client through my website @rickylaserart.
He asked, “Can you design a leather patch for me, ready to engrave, in just 1 hour?”
For me, this wasn’t just about creating another design — it was a chance to showcase how quickly and efficiently I work when the process is right.
In this blog, I’ll share the exact step-by-step process I followed to make a custom leather patch design — from client brief to final engraving-ready file.
Whether you’re a beginner, a designer, or someone starting a laser engraving business, this guide is for you.
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Table of Contents
😊 Affiliate & Content Disclosure
Some of the links on this website are affiliate links, including Amazon Associates links. This means that if you click on these links and make a purchase, I may earn a small commission — at no additional cost to you. As an Amazon Associate, I earn from qualifying purchases.
Additionally, some of the product images used on this website are generated using AI and are intended for illustrative purposes only. These images may not be an exact match of the actual product. For accurate visuals and product specifications, please refer to the official product page on Amazon.
I only recommend products that I believe are valuable and relevant to my readers. Your support helps keep this site running and allows me to continue providing useful content. Thank you!
🧠 Step 1: Understanding the Client's Idea
The first and most important step is to listen carefully to what the client needs. Ask clear questions like:
- What kind of leather patch do you want?
- Any specific size or shape?
- What text or logo should be included?
- Where will the patch be used — hats, bags, jackets?
Asking the right questions builds trust. The client starts to feel, “Yes, this person understands exactly what I want.”
Tip: Always keep communication friendly and professional — this saves revisions later.
🖥️ Step 2: Choosing the Right Design Software
After understanding the client’s idea, the next important step is choosing the right software to make the design. Since we are working on engraving, keep this in mind:
👉 Engraving art is always done in Black & White.
No colors, no gradients — just clear contrast. This helps the laser machine understand what to engrave and what to skip.
I usually use Photoshop, Adobe Illustrator, or Inkscape (which is free and great for beginners to make custom designs ). These tools give you full control over shapes, lines, and details.
🎯 Pro Tip:
- Always make sure the outer lines of your design are smooth and clean.
- Jagged or pixelated lines can confuse the engraving machine and give poor results.
- Zoom in while editing and use the smooth tool or pen tool for better curves.
🛠️ Step 3: Turning a Photo into a "Ready to Engrave" Leather Patch Design
The client sent me a photo and said:
“Bro, I want this image converted into a circular leather patch design, ready for engraving.”
Now this is where things got exciting! I used a powerful combo of tools to make it happen — AI, Photoshop, and Inkscape. Here’s the exact process I followed:
✅ 1. Using an AI Tool for Quick Conversion
I first uploaded the client’s photo on VectorDad.com, an online AI-based converter. This tool helps me turn regular photos into clean black and white artwork. Why B/W?
Because engraving machines only read black (to engrave) and white (to ignore). It’s super important to remove all colors and extra noise from the photo.
Tip: Make sure the image has clear contrast. Faces with shadows or background messiness don’t work well.
🎨 2. Cleaning and Adjusting in Photoshop
Once I got the basic B/W version from the AI tool, I imported it into Adobe Photoshop.
Here’s what I did:
- Removed the background completely
- Smoothed out outer lines.
- Adjusted brightness/contrast to make black areas sharper
Cropped it into a perfect circle shape (because the client wanted a circular leather patch)
🖋️ 3. Final Touch in Inkscape (for Engraving Format)
Lastly, I took the Photoshop file and imported it into Inkscape, a free vector design software.
Here’s why Inkscape is awesome:
- It lets you trace bitmap images and convert them into.SVG files (perfect for laser engraving)
- You can adjust stroke thickness and delete extra anchor points
- Most laser engraving machines love SVG or DXF formats, and Inkscape makes that super easy!
🔄 In just 20–30 minutes, I had a clean, circular leather patch design, ready to engrave, and fully approved by the client!
✅ Step 4. Converting the Design into DXF Format
For laser cutting, we need to convert the design into a DXF file.
- Visit Convertio Website: Open Convertio.
- Upload Your SVG File: Click on “Choose Files” and upload your file.
- Select DXF Format: Choose DXF as the output format.
- Convert and Download: Click ‘Convert’ and download your DXF file for laser cutting.
I personally use Convertio for DXF conversions, and it has never disappointed me. 
🔍 Step 4: Choosing the Right Material and Machine for Engraving
Once the design file is ready, it’s time to prepare for the actual leather patch engraving.
🧵 Material Selection:
For leather patches, you need real or faux leather that works well with your laser machine. I usually go with:
- Vegetable-tanned leather (great for crisp engraving)
- Or PU leather if the budget is limited
Make sure the surface is smooth and clean before engraving — it makes a big difference in the final output.
⚙️ Machine Selection:
For engraving, I personally prefer using laser machines like:
- xTool D1 Pro (very precise for leather engraving)
- ATOMSTACK (budget-friendly and works well with thin leather)
If you’re looking for a reliable engraving machine for leather patches, check out the one I use:
🧪 Test Before You Final Engrave:
Always do a test run on a scrap piece of leather before the final patch. Check:
- How deep the engraving is
- If the burn marks are clean
- Whether the design looks sharp in real leather
A small test can save your entire design from going wrong.
🔥 Step 5: Preparing for Laser Engraving
Once the “ready to engrave” leather patch design is finalized, it’s time to prepare for the actual engraving. This part is exciting, but you have to be a little careful, too.
🧰 Tools & Materials You Need:
- Laser Engraving Machine – I use this one from Amazon, which is beginner-friendly and precise.
- Vegetable-Tanned Leather Patch – Works best for clean engraving. Here’s a good option: Leather Patches on Amazon.
- Ventilation Setup – Leather can produce smoke/smell when engraved, so make sure you’re in a well-ventilated space.
🧪 Always Do a Test First
Before you engrave the final patch:
- Try your design on a scrap piece of leather.
- Make sure the engraving speed and laser power settings are correct.
- Check that the design is not too dark or too light.
🌀 Machine Settings That Work for Me:
- Speed: 500 mm/min
- Power: 40–50% (depending on the leather type)
- Passes: 1 (usually enough)
You can tweak these settings based on your machine. Just don’t forget — every leather patch is a little different, so testing helps a lot!
🎁 Step 6: Final Output & Things You’ll Need (with Links)
After engraving was done, the final leather patch looked amazing! It was clean, bold, and ready to be stitched onto a custom hat. The client loved it, and the fact that it was delivered so quickly made it even more special.
If you’re planning to make your own leather patch at home or for your brand, here are the tools and materials I personally recommend — these helped me complete this order professionally:
1. Blank Custom Hats
Perfect for stitching your leather patches:
Custom Blank Hats on Amazon
2. Leather Patch Material
Use real or faux leather sheets that are laser-safe:
Leather Sheets for Engraving
3. Laser Engraving Machine
Compact and powerful enough for small businesses or DIY:
Laser Engraver for Beginners
4. Polish or Leather Finisher
To give your patch a professional finish after engraving:
Leather Patch Polish / Conditioner
5. Tools I Used for Design
- Vectordad.com – to auto-trace the photo into black and white
- Photoshop – for basic cleanup and contrast.
- Inkscape – to finalize the vector and create a clean circle layout ready to engrave
✅ Final Thoughts
Designing a leather patch might sound tricky at first, but with the right tools, mindset, and a bit of practice, anyone can do it — even within 1 hour, like I did for this client.
I hope this step-by-step blog helped you understand the process and gave you inspiration to try it yourself. Whether you’re doing it for fun or business, creating custom patches is a great skill to have.
If you have questions or want me to create a patch for you, feel free to DM me on WP @rickylaserart! 
❓ Frequently Asked Questions (FAQs)
A leather patch is usually added to caps, bags, jackets, or jeans to give them a premium and customized look. It’s often engraved or embossed with logos, quotes, or designs.
Yes! With the help of online tools like Photoshop, Inkscape, or AI vector tools, beginners can easily create their first leather patch design.
You should always use a black and white (B/W) vector format like SVG, EPS, or high-res PNG. This ensures clean and sharp engraving results.
Tools like VectorDad.com are great for beginners. You can upload a photo and get a clean B/W version suitable for laser engraving.
Vegetable-tanned leather works best for engraving. It’s natural, engraves deeply, and leaves a nice burn mark. You can easily find quality leather here (affiliate link).
Yes, both work well! Glowforge is beginner-friendly and produces professional results. Check out this one here (affiliate link).
It’s optional, but polishing with a leather balm or finisher gives the patch a clean and professional look. You can try this top-rated leather polish here.
You can use strong fabric glue or stitch it manually. Some hats come with pre-sewn patch spaces. Check out some custom hat bases here (affiliate link).
If you have the design ready, engraving takes just 5–10 minutes. Designing might take 30–60 mins, depending on complexity and tools used.
Absolutely! People love personalized patches for their brands, teams, or events. You can sell on Etsy, Instagram, or your own website.
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😊 Affiliate & Content Disclosure
Some of the links on this website are affiliate links, including Amazon Associates links. This means that if you click on these links and make a purchase, I may earn a small commission — at no additional cost to you. As an Amazon Associate, I earn from qualifying purchases.
Additionally, some of the product images used on this website are generated using AI and are intended for illustrative purposes only. These images may not be an exact match of the actual product. For accurate visuals and product specifications, please refer to the official product page on Amazon.
I only recommend products that I believe are valuable and relevant to my readers. Your support helps keep this site running and allows me to continue providing useful content. Thank you!
