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There are really no standard sizes however for hats you can only go 2" or so high depending on the hat. For others I would say round 3" is a popular size.
 
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You're in the business of making patches. Your website has a whole section on it. You can't be serious asking this question?
probably hoping for keyword hits from search queries here or outside search engines
guerrilla marketing

i'm still waiting for some type of response to their underground printing thread
why ask a question seeking help and never return, unless it is made for marketing purposes only?
 
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