🔥 Single vs. Dual Heated Platen Hat Presses: Which is Better for Adhesive-Backed Patches?

When it comes to applying adhesive-backed patches to hats, heat matters—a lot.

You'd have better luck flying blind than testing an adhesive without knowing the specs of that adhesive or having the right tools for the job, Proper prep for pressing will involve seeking out the information that will ensure both of those questions are answered. Whether you’re running a boutique hat brand or a full-scale production shop, the type of hat press you use can make a big difference in patch adhesion, production efficiency, and final product quality.

In this post, we’ll break down the key differences between single heated platen and dual heated platen hat presses, especially when working with adhesive-backed patches like those backed with Durra-Bull™, a high-performance American-made adhesive known for durability and resilience.

🎩 What is a Hat Press?

A hat press (or cap press) is a specialized heat press machine with an upper and lower platen designed to conform to the curved surface of a hat or cap. It uses heat and pressure to bond materials—like vinyl, transfers, or adhesive-backed patches—to the fabric. It can come with interchangeable or replaceable platens, or may need other modifications in order to best suit your job. 

There are two main types (& bonus options):

• Single Heated Platen Press: Heat only from the top platen; the bottom (or base) remains unheated. Popular models: Vevor (4-in-1 or Automatic), Delclynee or older Hotronix® models
• Dual Heated Platen Press: Both the top and bottom platens heat up, providing consistent heat to both sides of the hat and patch. Popular Models: LoneStar Adhesive's Branding Iron or Stahl's Hotronix® 360 IQ®
• Bonus Options: Some of our customers are extremely patient and will make a heat gun or Cricut handheld press work for them until they can upgrade. Our caution is that you work to ensure consistent results each time and use common sense safety measure like Heat Resistant Gloves!
  
  

🔥 Single Heated Platen Press: Pros & Cons

✅ Pros:

• Cost-Effective: Generally more affordable, making it a good starting point for smaller operations.
• Widely Available: Easier to source and operate with less setup complexity. Many are available on Amazon!
• Simplicity: Fewer variables to manage for beginners. (Caution: Having the adjustable pressure functionality is necessary- steer away from presses that will not allow you to make these adjustments or learn how to mitigate this loss of function effectively!)

❌ Cons:

• Limited Heat Penetration: Since only the top side is heated, adhesive activation may be slower or uneven—especially with thicker patches or hats with structured panels. This CAN often be mitigated with a pre-press of the hat to warm the material and activate the adhesive sooner, but... time is money where order volume is concerned.
• Risk of Undercuring: Adhesives like Durra-Bull™ require a thorough heat soak; insufficient bottom heat can lead to poor adhesion or delamination over time. 
• More Pressure Required: Operators often compensate for the lack of lower heat with excessive pressure, which can damage hats or distort patch shape.

🔥 Dual Heated Platen Press: Pros & Cons

✅ Pros:

• Even Heat Distribution: Delivers heat from both top and bottom for faster, more consistent bonding—especially important for thicker patch materials, densely layered hats (corduroy or wool) or premium adhesive-backed patches. 
• Improved Adhesion: Ensures adhesives like Durra-Bull™ fully activate and flow into the fibers, creating a stronger and longer-lasting bond. Since our adhesive is a polymer that liquefies at our recommended temperatures, you are using a combination of heat and pressure to fuse the adhesive through the fabric to which you're applying a patch. Therefore, proper heat application is imperative!
• Faster Production: Reduced pressing times with consistent results across batches. Again... time is money when orders increase in volume.
• Better for Complex Materials: Ideal for top grain leather or acrylic patches, dual-layer silicone, PVC patches and thick twill bases.

❌ Cons:

• Higher Cost: More expensive upfront than single platen options, but used models are fairly easy to find. Check the Featured section of our Facebook group for the Equipment for Sale thread!
• Learning Curve: Requires fine-tuning temperature and time settings for both platens to avoid scorching or overcooking.
• Heavier Footprint: Often larger and heavier—consider workspace limitations.

So Which One Should You Choose?

Use a Single Heated Platen Press if:

• You’re doing low to moderate volume.
• Your patches are thin and flexible, or you make accommodations for thicker materials.
• You’re just starting out and working on a budget. Not everyone can "buy once, cry once," and that's ok.

Use a Dual Heated Platen Press if:

• You’re applying premium adhesive-backed patches like those with Durra-Bull™ in a variety of materials.
• Those materials are thick, dual-layered, or heat sensitive.
• You want faster press cycles and stronger adhesion for high-quality or high-volume jobs.

Your patch deserves more than a quick stick—it deserves a bond that lasts. While single platen presses can get the job done for light work, a dual heated platen press offers superior performance, especially when working with high-end materials and adhesives. That said, we have many amazing makers in our Facebook group showing off high volume and fast turnarounds with single platen presses. It can be done with determination!

At LoneStar Adhesive, we design our Durra-Bull™ adhesive-backed patches with heat press application in mind—and they shine brightest when used with even, consistent heat and adequate pressure. How you piece those two factors together can affect your outcomes, so be sure you have a solid control on both to create a bond that lasts!

Want help picking the right heat settings for our patches? Check the FAQ section of our website (bottom of the homepage) and join us over in the best place for makers - LoneStar Adhesive Official Group.