Custom hats are one of our most-loved products, and for good reason: they’re extremely versatile. They’re a solid addition to a uniform, make a memorable giveaway for a trade show or fundraiser, and add a fun flair to personal events like weddings, family reunions, or even pub crawls.
Not sure which hat will work best for your design? Want a better understanding of the different styles we offer? Here’s the lowdown on the different types of hats you can customize with Blue Cotton and where each style shines — along with a few product recommendations to help you get started.
What to Look For in Hat Blanks
Small details in construction can make a huge difference later on, no matter the style or brand you choose. If you want your hats to look great down the road, your first steps matter.
- Stitching: Look for durable stitching that will stand up to years of wear. The stitches should be tight and even, and the thread should look smooth and have a consistent diameter throughout. Keep an eye out for loose stitches, frizzy thread, and flyaways.
- Structure: Structured hats should be sturdy and hold their shape. If you’re choosing a six-paneled hat, make sure that the front seam is centered and the front panels are the same height. Unstructured hats should have a relaxed fit, but the fabric should never feel flimsy or low-quality.
- Materials: The materials used will affect not only the look of your hat, but its performance as well. While cotton is a classic choice for everyday wear, you may wish to choose a moisture-wicking polyester when making hats for an outdoor crew or sports team, or a substantial wool blend for premium merchandise.
- Fit: If you’re embroidering fitted caps, rather than adjustable-fit caps, ask to see multiple samples of the same size to evaluate fit consistency. If the fits don’t match, reorders can get a little messy.
We offer premium embroidery and screen printing for baseball caps, snapbacks, trucker hats, visors, and bucket hats in a range of styles and price points, so you can always find something that will look great and fit your budget.
Baseball Caps
A timeless favorite since the 1860s, the baseball cap has long outgrown its roots on the field. These days, baseball caps are an indelible part of the fashion landscape, whether in team uniforms, streetwear, or casual outfits.
Structure
Baseball caps typically have six structured panels and a stiff brim, though recently the occasionally you’ll find five-paneled designs have gained a lot of popularity. Six-paneled hats have a more fitted silhouette around the head, while five-paneled hats give a flatter and often taller look in the front.
Structured hats will have added support sewn between the fabric layers of the front panels, which helps the hat keep its firm, defined shape whether or not you’re wearing it, while unstructured hats (AKA dad hats) offer a more relaxed, casual fit. Some baseball cap styles have a small button at the crown, usually covered in the same fabric as the rest of the hat.
Five-paneled baseball hats offer ample uninterrupted space for larger designs, making them a fantastic choice for complex logos that benefit from being scaled up, though they can also look great on six-paneled hats with the right embroidery technique.
Fabric
Baseball caps can come in a wide variety of fabrics, including cotton, cotton twill, canvas, polyester, denim, corduroy, or wool blends. The choice of fabric will affect the stiffness, comfort, and breathability of a hat, with wool blends offering durable structure and cotton twill giving a softer and more worn-in fit.
Embroidery works best on heavier and more structured materials that can support dense stitching. Our custom ball caps are available in 100% cotton, 100% acrylic, 100% polyester, cotton-polyester blend, or composite blends.
Fit
Baseball caps are available in both fitted and adjustable styles. Some have multi-holed plastic straps that snap into place, while others have either velcro or fabric-strap closures. If ordering for a team or promotional giveaway, we recommend opting for customizable sizing.
Snapbacks
Named for the adjustable plastic strap that gives this variation of the baseball cap its precise custom fit, snapbacks are both a classic style and a modern streetwear statement, making them a fashionable choice for almost any event or team uniform.
Structure
Snapback hats with internal support are an amazing option for embroidery. The structured front panels create an optimal canvas, keeping your design looking sharp even when your hat is just sitting on a shelf. Unstructured hats made from heavier fabrics can also deliver stunning results.
Like most baseball caps, snapbacks traditionally come in five-panel and six-panel variations. For larger designs that span most or all of the front of the hat, consider opting for a five-panel snapback for a more seamless look.
Fabric
Just like the traditional baseball cap, you can find snapbacks in a variety of materials, including wool, cotton, twill, or polyester. Our selection includes 100% cotton, 100% polyester, and 100% acrylic, along with high-quality blends. Stiffer fabrics help prevent puckering during the embroidery process. If you’re not sure which fabric to choose for your order, reach out to our team for a quick chat or to request a sample.
Fit
The fit of a snapback cap is easily adjusted using the plastic snap closure at the back of the hat. This is great news if you’re ordering custom hats in bulk for a sports team, workplace, fundraiser, or a personal event like a bachelor party or family reunion, as you won’t need to worry about ordering different sizes. When choosing your blanks, check that the sizing strap is firmly fastened to the hat.
Trucker Hats
The trucker hat is the less formal cousin of the snapback baseball cap. This classic hat surged in popularity in the early 2000s thanks to its retro flair, and it remains a popular streetwear accessory today. Unlike snapbacks, trucker hats have breathable mesh panels, so they’re a great choice for warmer seasons or climates.
Structure
Trucker hats are panelled caps with a high crown that give a taller, sometimes oversized appearance. The back of a trucker hat is made up of four mesh panels, while the front may be one panel that curves to fit the head or two panels connected by a center seam.
Again here, your best option will depend on your preferred design size and placement. If you want a larger, centered design, opt for a single-panel cap. If your design will be smaller and placed off-center, either style could work.
Fabric
The mesh panels in the back of most trucker hats are made with nylon or polyester. The front is most often made with polyester foam, but you can also find trucker hats made with structured denim, canvas, twill, linen, or cotton. Foam trucker hats are an excellent canvas for both regular and 3D embroidery, thanks to the stiff front panels. We offer custom trucker hats in both foam and durable fabric styles, giving you more control over your final look.
Fit
Like the snapback, you can customize the fit of a trucker hat using the adjustable plastic snap band at the back. Being one-size-fits-all, they’re a great pick for promotional giveaways, merchandise, event gear, or team uniforms.
Visors
Visors are a great way to shade your eyes from the sun while still enjoying an open-top design that helps you stay cool during sweaty activities and sunny days. As a bonus, these hats accommodate a far wider range of hairstyles, so top knots and bigger hairdos aren’t really an issue.
Structure
Visors have a stiff brim attached to a wide, structured band, which can accommodate text-based or graphic designs. Embroidery can be added to the center of the band, on either side of the band, and even in the back. With less space available to embroider, visors work best for smaller symbols or wordmarks, rather than complex logos or artwork.
Fabric
Visors come in a variety of fabrics. Those best for casual, everyday wear are often made with cotton, polyester, acrylic, or twill. Specialty visors made for athletes may be made with sweat-wicking microfibers or French terry. We offer custom visors made from 100% cotton, 100% acrylic, 100% polyester, cotton-polyester blend, or nylon/cotton twill.
Fit
Visors are typically adjustable and usually feature a velcro or fabric strap, though they’re also available in snapback styles. Their customizable fits and ability to complement most hairstyles make them a smart choice for promotional giveaways and merch. Aside from being the classic choice for tennis players around the world, their breathability also makes them a great uniform option for teams that work outdoors, like landscapers, lifeguards, or park rangers.
Results
While they may have a smaller surface area, visors can still look great when embroidered.
Our Top Visor Brands
Quality is key when choosing blanks for custom hats, whether you’re embroidering or screen printing. Look for strong stitching and reinforced seams that will hold up to daily wear, with durable, colorfast materials that can withstand the elements, and consistency in fit and construction.
Here are a few of the brands we love for custom visors.
Richardson
Best for workwear, outdoor crews, long-term wear, and athletic wear.
Richardson hats are built to last. With their focus on practical, performance-driven athletic products, Richardson delivers on durability and reliability.
Pros:
- UV-shielding to block solar radiation
- Breathable fabrics
- Classic styles
- Can be spot-treated and hand-washed with a light detergent
Cons:
- As their caps are handmade, there may be slight color variations between batches
Yupoong
Best for lifestyle merchandise, trade teams, and relaxed branding.
Known for their iconic FLEXFIT® brand, Yupoong’s hyper-trendy caps are constructed with strong attention to detail and are popular in streetwear fashion.
Pros:
- Deep catalog of classic and trendy styles
- Stretchy, comfortable fits
- Fade-resistant materials
- Durable, high-quality construction
Cons:
- Less luxurious than more premium options
Valucap
Best for promotional giveaways, corporate gifts, community events, and children’s sports.
Offering solid construction and classic styles with affordable pricing, Valucap is a popular choice for projects that need to stick to a budget.
Pros:
- Budget-friendly
- Soft materials
- Comfortable fit
Cons:
- Less durable than higher-end brands
Popular Hats for Embroidery
Baseball Caps: One of our biggest bestsellers, the six-panel VC300 Valucap Bio-Washed Cap comes in 36 vibrant colors and camo patterns, with contrast stitching options. Made from 100% bio-washed chino twill, it has a comfortable, unstructured fit. Its adjustable strap and antique brass buckle allow it to fit sizes 6 ⅝ to 7 ⅜.
Snapbacks: If you’re looking for a snapback that stands out from the pack, our flat-billed 256 Richardson Umpqua Snapback Cap is an excellent choice. Its UV-shielding cotton-nylon blend offers UPF 50+ protection and comes in 12 eye-catching color combos, elevated by its chic braided rope trim.
Trucker hats: Our bestselling 6006 YP Classics Five-Panel Classic Trucker Cap is a five-panel trucker hat in the timeless dad cap style. It comes in 28 colors and features a trendy flat brim paired with a high silhouette. The OFA LEGACY Old Favorite Trucker Cap is another popular choice. Available in 36 colors, this hat features a lower profile, a relaxed fit, and a curved visor covered in fashionable distressed cotton twill.
Visors: Looking for something to keep the sun (and sweat) out of your team’s eyes? The STC27 Sport-Tek PosiCharge RacerMesh is a moisture-wicking performance visor that’s both colorfast and durable, and the adjustable hook-and-loop closure ensures a snug fit for your whole squad. For added visual flair, consider the STC13 Sport-Tek Dry Zone Colorblock Visor, which features a sporty colorblock detail on the band.
Whichever hat you choose, here are a few tips to make sure your design looks great:
- Avoid using too many visual elements or colors. Bold, simple designs look great and go a long way.
- Choose hat blanks that contrast with your design’s colors so that your art pops against the fabric.
- Pick your embroidery location carefully. Our order builder and design studio let you preview different sizes and placements so you can order with peace of mind.