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Check your local shopping mall. I know here in Denver at the Colorado Mills mall there is an embroidery shop that does t-shirts, hats, hoodies, etc. on a piece by piece basis, 1 or 1,000.
It's funny you posted about making a Phoenix Foundation hat. I'm working on a project of my own, the details of which will be posted soon, hopefully by this weekend, if all things work out the way I'm hoping.
Your design immediately reminded me of the patches, or they could be stickers, seen on the jackets of the guys MacGyver led into the forest in the episode "Invisible Killer". I say they could be stickers, made to appear like patches, because in "Star Wars: EIV" the Imperial Cog "patches" seen on the shoulders of the various imperial personnel were in fact stickers. It's much cheaper to make stickers than to have patches embroidered and then sewn on to a costume that will only be worn for a few scenes.
 "Jeep. My Jeep? What are you talking about? Penny! My Jeep?" - MacGyver
"Look at me. I'm a hurtin' guy! I'm beat up. I need a month's worth of sleep . . . and I need a haircut!" - MacGyver
"It's been said, 'The best gift a man could ever give another, was his life', Jack Dalton was never one to settle for less than the best. Thank you Jack." - MacGyver
"Reboots are born out of the lack of imagination." M. Lance Frank
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