Custom Hats & Headwear Buyers Guide - Merchology

Custom hats are one of the most popular pieces of custom apparel for a good reason. With custom hats, you can prominently display your company logo or design right where people direct their gaze. In addition to that, custom logo hats are very affordable in comparison to some other types of promotional apparel. In this guide, we’ll break down the different styles of custom hats, list the headwear brands that we offer, explain how your logo is added to custom headwear and show how you can use custom hats to promote your business.

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What Custom Hat Brands are Offered?

At Merchology we offer customization of over 30 of the top brands in headwear and our brand offerings are always growing. Some of our most popular custom hat brands include New Era, Under Armour, Richardson, Nike, Carhartt, and Flexfit. Check out our brands page to see our complete list of brands that you can personalize with your corporate logo or custom design or refer to some of our most popular custom headwear brands below. 

Which Custom Hat Styles Are Offered?

There are countless styles of hats out there that come in all shapes and sizes. In this exercise, we won’t dive into bowlers, boaters, berets or other novelty hats. Instead, let’s focus on the types of hats that are best suited for customization for your team or company.

Custom Baseball Caps

The baseball hat is where it all started. These custom baseball hats have a medium sized curved bill and offer a great space on the front of the hat for logo embroidery. If you’re actually going to play baseball in these, consider our selection of moisture-wicking hats!

Custom Snapback Hats

Snapback hats are one of the most in-style hat types out there right now. These custom snapbacks aren’t just stylish though, they’re easily adjustable using two pieces of plastic that snap together to form the perfect sized hat for anyone.

Custom Trucker Hats/ Mesh Back Hats

Trucker hats are another classic American style. These custom trucker hats feature 100% polyester mesh backing, making them an extremely breathable headwear option. Trucker hats are most commonly structured hats with snapback adjustment but can also be fitted.

Custom Structured Hats

Structured hats offer a stiffer and supportive fabric inside the hat that holds their shape. These are the same construction of hats that are worn by professional baseball players at the highest level.  Each of the last three hat styles mentioned feature a structured construction more often than not.

Custom Unstructured Hats "Dad Hats"

Unstructured hats, on the other hand, do not have supportive fabric to hold the shape of the hat. These unstructured hats, also known as “dad hats”, are softer and can be more comfortable than structured hats.

Custom Fitted Hats & Flex Fit Hats

Both custom fitted hats and custom flex fit hats feature a closed back and are NOT adjustable. These fitted hats are measured in 1/8 inch size increments and typically have a structured construction. Fitted and flex fit hats are also worn by professional baseball players and make great athletic and hats.

Custom Flat Bill Hats

The name says it all for flat bill hats. These custom flat bill or flat brim hats can come in a variety of colors and materials, but they all feature a flat bill rather than a curved one. Custom flat bill caps are usually either fitted or snapbacks.

Custom Hook & Loop Closure Hats

Hook and loop closure hats come in many shapes, fabrics, and colors, but are always adjustable. Rather than using a plastic snap closure like snapbacks or a buckle closure these custom hook & loop closure hats typically use Velcro for size adjustment. This hat style is especially popular for athletic hats and golf hats.

Custom Buckle Closure & Strapback Hats

Buckle closure or strapback custom hats are most commonly unstructured hats and feature a self-strap metal buckle closure. Custom strapback hats have an old school, traditional look to them and make ideal casual custom headwear.

Custom Cotton Hats

This might be more of a material than a style, but its worth mentioning that custom cotton hats provide some unique benefits that other hats can’t. For example, cotton custom hats are more breathable, versatile, inexpensive, durable and softer than other hats. Custom cotton hats are often the choice for promotional hats.

Custom Bucket Hats

The custom bucket hat is the ultimate choice in leisure headwear. Custom bucket hats have a wide brim that goes around the perimeter of the hat to keep the sun off your face and keep you cool, making them the perfect summer hats.

Custom Beanies & Winter Hats

Custom logo beanies, fleece hats, and knit caps are the perfect way to stay warm while spreading your brand all winter long. These custom stocking caps come in wool, cotton, acrylic, and fleece and are available in a variety of styles.

Custom Visors

Are visors hats? Today we're going to say yes. Custom visors are the best of both worlds, they keep the sun out your eyes while still letting your head breathe. Custom visors are most commonly used as golf visors, tennis visors or for other athletic applications.

Custom Headbands & Ear Warmers

Another piece of headwear that pushes the boundaries of the definition of a hat. Custom headbands are the best way to keep your ears warm in cold weather without messing up your hair! Custom headbands are also popular as athletic headwear.

Custom Hard Hats

These custom hard hats obviously aren’t your everyday headwear unless you work in an environment that requires them. But if you do, there’s no better way to stay safe on the job site. We offer a variety of hard hat styles including regular brim hard hats, full brim hard hats, and cowboy style hard hats that meet OSHA and ANSI protection regulations.

How is My Company Logo Added to Custom Hats?

There are a few different decoration methods that can be utilized to add your corporate logo to our selection of custom hats depending on the style of headwear selected and the appearance you want to achieve with your design.

Custom Hat Embroidery

The most popular and recommended decoration type for headwear is custom embroidery. Embroidery is ideal for personalized hats because embroidery can be performed on non-flat surfaces, unlike many other decoration methods. Embroidered logos and designs are also durable and provide a stylish and sophisticated appearance. Read how commercial embroidery is done in our Guide to Custom Embroidery.

3D Puff Embroidery

Similar to standard embroidery, 3D puff embroidery is used to add a textured element to your logo or design. However, with 3D puff embroidery, there is an added layer of foam that provides more dimensional depth to your custom hat. 3D embroidered hats are also extremely durable and sharp but tend to be more expensive than traditionally embroidered custom hats because of the added fabric. Check out how it’s done in our Guide to 3D Puff Embroidery.

Where Can My Logo be Embroidered on Custom Hats?

Your logo placement options are going to differ depending on the custom headwear you’ve selected, but our standard logo locations are front and center, left side, right side and back of the hat. These are the locations on your custom headwear that will display your logo most prominently. 

Applications for Custom Hats & Headwear

There’s really not many situations that custom hats can’t come in handy. Whether your trying to keep the sun out of your eyes, stay warm, stay safe, or simply promote your business, there’s a custom hat for any application.

Promotional Hats

This one is pretty broad because any hat that you add your custom embroidered corporate logo to can be a promotional hat. However, we’d be remiss if we didn’t mention this because custom hats are one of the most popular ways to generate brand awareness through corporate apparel. Custom logo hats are perfect for trade shows, recruiting events, new hire packages and much more.

Custom Golf Hats

Your golf attire isn’t complete without a custom golf hat. Get your corporate logo embroidered on personalized golf hats from the best brands in golf including Under Armour, Nike Golf, Titleist, Callaway, Puma Golf, AHEAD, Adidas and TaylorMade. Many of the custom golf hats we offer provide sweat wicking performance fabric and UPF protection to keep you cool and dry on the golf course.

Custom Baseball Team Hats

We’ve got you covered for custom baseball caps at any level of competition. Little League team hats, company softball team hats, or professional baseball team hats – you name it. We offer custom baseball caps from some of the top brands in baseball including New Era, Richardson, Flexfit, and Under Armour.

Custom Uniform Hats

A custom hat with your embroidered company logo is the perfect piece of corporate apparel to complete your work uniform. You’ll find the perfect uniform hats for your business whether your custom uniform hats are for industrial uniforms, high visibility uniforms, sports uniforms, retail uniforms, restaurant uniforms, hospitality uniforms, or any other kind of custom uniform.

Camo Hats & Custom Hunting Hats

Our selection of custom camo hats makes perfect hunting hats, fishing hats or outdoor hats in general. Now you can embroider your logo on camouflage hats and camo beanies from New Era, Flexfit, Port Authority, AHEAD, Under Armour and Richardson.

Work Hats & Safety Headwear

Custom headwear plays a large role in custom workwear and safety apparel. In many occupations, you need custom high visibility headwear to stay visible or flame resistant headwear to be protected from exposure to fire or electricity. In many other industries, it is required for employees to wear custom hard hats to provide protection from impact. Our most popular brands for work hats and safety headwear include Carhartt, Under Armour and OccuNomix.

Custom Sports Hats & Athletic Headwear

We’ve already touched on baseball caps and golf hats, but there is much more to athletic hats than that. Check out our collection of custom moisture wicking hats & sweat-wicking hats for the perfect workout hats or running hats from activewear brands like Under Armour and Nike.

Custom Sun Hats

Kick back and relax in a custom sun hat with your corporate logo. Styles of sun hats include custom bucket hats, safari hats, lifeguard hats, boonie hats, straw hats, beach hats and other full brim hats. Pair these custom summer hats with one of our custom fishing shirts for the perfect leisure outfit.

Embroidered Winter Hats

Sorry to go straight from summer to winter, but you’ll thank us when your ears are warm! Popular styles of winter headwear you can customize include custom beanies, slouch beanies, pom beanies, fleece hats, knit hats, and headbands.

Time to Customize Your Own Hats

Whether it’s protecting your skin, covering up a bad hair day, or rounding out an outfit, hats serve a lot of purposes. Whether it’s for practicality, style, or convenience, the right one can be just as much a necessity as it is an accessory.

Want more information on custom team hats? Feel free to contact us.

But not everyone is looking for the same thing in their headwear. When you’re trying to reach a specific market, picking the right custom hat can help ensure your apparel gets worn and shows off your brand in the process.

While picking your hat option doesn’t have to be overly complicated, there are enough factors at play that you should still think it through carefully before printing. Here’s what to look for when shopping for custom headwear and how to choose the option that suits your brand best.

Why Custom Hats Are a Must-Have

Whether you’re using them as trade show giveaway items, selling them, wearing them, or giving them out as corporate gifts, custom hats can be an invaluable part of your branding efforts — and your wardrobe. No matter what you plan to use them for, here are some of the benefits custom hats can bring.

• Distinctive Branding: Custom hats are perfect canvases for showing off your company logo because they can be worn anywhere, displaying your brand indoors and outdoors. Whether they’re given away or deployed as employee apparel, they convey a sense of professionalism and legitimacy.
• Personalization Capabilities: Whether you want bold color combinations, tastefully subtle designs, or dynamic logo placement, custom hats offer a range of personalization possibilities.
• Versatile Uses: Custom hats make great gifts, event keepsakes, team gear, product inventory, or new hire swag.
• Memorable Gifts: Sure, you could give a gift card — but you could also give a gift they’ll remember (and wear) for years to come. Custom apparel like hats make for surprising, thoughtful gifts.
• Impactful Company Swag: To boost morale and show your team they’re seen and valued, you can give your employees hats customized with their names or roles, which they can in turn wear outside the office to show off your brand.

Top Personalized Hat Styles to Consider

Not sure where to start on your search for the best custom hat? From trucker hats to visors, you’ve got plenty of options to consider. Here are some of the most popular hat options and some key features to think about.

Beanies

A great choice for places where the temperature drops, custom beanies offer warmth and boast style. Made from materials like wool, cotton, or synthetic blends, these hats are ideal for casual aesthetics and may not be right for every brand.

Yupoong Cuffed Knit Beanie

Baseball Hats

These are classic options that can suit just about any market. With fitting options like adjustable straps, snapbacks, Velcro, or buckles, custom baseball hats are a versatile choice that can suit athletic and casual wear.

Big Accessories 5 Panel Cotton Baseball Cap

Trucker Hats

With their foam front panels, breathable mesh backs, high crown, and adjustable snapback closures, custom trucker hats are the perfect lightweight option for brands that pair well with a laid-back (or throwback) style. As an added bonus, the foam panels offer a bold surface for your custom designs.

Nike Snapback Mesh Trucker Cap

Dad Hats

For markets that prefer a more relaxed aesthetic, custom dad hats sport a vintage feel with their soft, unstructured panels, low crown, and pre-curved brims. This understated style works best with subtle embroidery or small logos.

Adam's Optimum Low-Profile Cotton Baseball Cap

Rope Hats

Structurally, this type of hat can take on just about any form, from baseball to trucker. But custom rope hats add a decorative twist with a corded “rope” detail running across the base of the crown. This retro-inspired element matches bold branding for those who want a unique look.

Adidas Sustainable Rope Cap

Fitted Hats

This type of hat offers a more polished, tailored appearance with no adjustable closures. Keep in mind that custom fitted hats are available in specific sizes only, making accurate sizing crucial, and meaning that this isn’t ideal for those looking for giveaway options or simple one-size-fits-all apparel.

Under Armour Blitzing Curved Cap

Visors

In some ways this style is kind of an anti-hat, featuring an open-top design and a brim for sun protection. Lightweight and functional, custom visors are ideal for markets interested in sports or for promoting outdoor events. However, keep in mind that customization opportunities for this style are a little limited.

Port & Company Fashion Visor

Bucket Hats

For a casual, streetwear-inspired retro look, custom bucket hats are a trendy choice. Their soft, unstructured design with a wide, downward-sloping 360-degree brim allows for lots of customization opportunities.

Oakley Team Issue Bucket Hat

Flat Bill Hats

Custom flat bill hats are distinguished by their (you guessed it) flat brims, making them a solid option for sports fans and those with more refined headwear style tastes. These hats cater to bold, sharp designs that appeal to trend-conscious audiences.

Flexfit Pro-Performance Flat Bill Hat

Safety Hats

Designed with workplace protection in mind, custom safety hats can also be customized with company logos or safety messages. It probably goes without saying that this class of hats is limited to those whose audience needs them for work.

Big Accessories Hi-Vis Baseball Cap

Popular Hat Brands For Customization

Just about every major apparel brand offers custom headwear options. As you might imagine, custom hat quality, price, materials, and style options can vary widely from one to the other. Whether you’re looking for premium athleticwear or affordably casual options, you can probably find what you need from one of these top brands.

• Richardson: Known for their high-quality craftsmanship and versatility, Richardson specializes in custom hats for sports teams, outdoor enthusiasts, and lifestyle brands.
• Nike: A brand that needs no introduction, Nike boasts sleek, performance-driven custom hats. From lightweight visors to structured caps, their premium hats come in just about every structure and fabric type you can imagine.
• New Era: Renowned for their iconic fitted caps, New Era is the official supplier for Major League Baseball and a fan favorite for casualwear. Their premium-quality hats are perfect for bold, intentionally styled custom designs.
• Adidas: custom Adidas hats offer sporty aesthetics with comfort and performance. Known for their clean, minimalist designs and breathable materials, their hats appeal to activewear enthusiasts.
• Carhartt: Built for durability and functionality, Carhartt hats are ideal for workwear and rugged outdoor branding.
• Under Armour: Specializing in performance gear, Under Armour custom hats are designed with moisture-wicking materials and athletic-focused features.

How To Choose The Right Custom Embroidered Hat

While there is no universal right answer to the question of which custom hat style is best, there are a few things you should think through that’ll help you pick the best one for your brand.

• Determine the Purpose: Start with the purpose of the custom hat. Is this hat for promotional branding, team uniforms, giveaways, or personal use? The purpose will help you narrow your choices down by giving you insights into which styles may be best suited for those needs.
• Consider Your Audience: Your purpose should lead you to your audience. Younger, style-minded people may prefer flat bill hats or bucket hats, while older or more casual groups might lean toward dad hats or trucker hats.
• Pick a Style: As outlined in the section above, there are tons of hat styles out there that cater to many different use cases. Choose one that aligns with your brand, audience, and goals — you can deal with specific characteristics after.
• Weigh Brand vs. Budget: Is a premium brand like Nike or Adidas important for reflecting your brand’s quality? Or, are you more price-sensitive and willing to sacrifice name recognition to save on costs? This should help you cut down on your options since it’ll have big impacts on your per-unit pricing.
• Look Into Materials: Materials impact comfort and functionality, which harkens back to your audience and purpose. Cotton and blends are lightweight and breathable, while wool is warmer for cold-weather styles like beanies. Meanwhile, performance fabrics with moisture-wicking or UV-protection features work well for activewear or outdoor use.
• Apply Branding: Some hat options will have more limited color choices or logo placement possibilities than others. Remember, branding is more than just your logo. Apply your custom designs to your hats, but also look for colors and fonts that align with your broader brand style book.

Simplifying Custom Hats From Design to Delivery

At RushOrderTees, we simplify the process of creating the best custom embroidered hats and custom printed hats by offering a massive array of hat styles across the biggest apparel brands, a convenient design platform that shows you your mockup in real time, and an array of shipping options that can meet just about any deadline.

Just start with a hat style or brand, browse product options that suit your budget and printing volume needs, pick a color, and then head to our design studio to see what your product will look like. Upload your design and make edits to size and placement as needed, or start a new design from scratch.

Once you’ve got your design finalized, just select a quantity and shipping timeline and your custom hats will be where you want them when you need them.

The Right Custom Apparel for Your Needs

There’s a lot to consider when picking the perfect hat for a custom design, but it’s well worth taking the time to decide on the right style, brand, and design for your audience. The perfect hat should communicate your branding effectively while helping you meet your product or marketing goals and staying within budget.

Looking for more than just a hat? Whether you want items to sell, to give away, or for publicizing an event, RushOrderTees has the custom apparel and promotional items you need to market your company, drive revenue, or build employee morale.

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