Hats & Headwear

The single most important choice in custom headwear is structured versus unstructured. A structured cap has buckram in the front panels that holds the crown upright, giving embroidery a flat, stable surface — this is what you want for a detailed logo or 3D puff. An unstructured dad hat sits soft against the head and reads more casual, but intricate artwork distorts as the panel flexes. Trucker hats sit in between, with a structured foam front and mesh back. Embroidery is standard. Flat embroidery suits fine detail and small text. 3D puff embroidery lifts letterforms off the cap and looks sharp on bold, simple marks — it does not work for thin lines or small type. Knit beanies take a woven label or a direct embroidery depending on the knit gauge. Minimum order quantities are set per item, typically 100 to 250 pieces. We cover up to 3% spoilage and keep your digitized file for two years, so reorders carry no setup charge.