My son's robotics team is wanting to buy beanies with their logo on them. I'm playing around with some ideas before pitching to them that I can make these for less than they are going to pay online. I did the design on felt and then sewed it to a premade hat from Walmart. Cost me about $3 to make ($2 for the hat) and the team was going to pay $22 each. I have a second hat that has a smaller logo and an oval around the design. Not sure which I like better. I just have to figure out how to sew the patch on straight :) It starts off straight and I pin it, but when I'm done sewing it is just a tad bit crooked.
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