Need Help with Hat Patches

Hey, I'm new to doing patches on hats and could use some help.

Based on my research the best way to do this is to get the shapes pre-cut out of patch material (I assume it's a type of canvas) and tack it down with the embroidery machine and do the design that way. I don't have someone that could sew on a pre-done patch.

I've tested this will twill but it doesn't have the same look/feel as a traditional patch.

Am I missing anything here? If getting pre-cut patches is my best bet, do you have any suggestions on where to source them from?

Thanks in advance for any help you might be able to offer!