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custom hat embroidery

Last updated on August 22nd, 2022 at 03:14 pm

Whether you are you planning employee uniforms, company stores, community events or tradeshows, custom hats are always everyone’s favorite! Choose from custom fitted hats, dad hats, snapback hats, baseball caps, bucket hats, trucker hats, beanies – the options are endless when it comes to custom hats personalization. Custom hats with embroidery is long lasting, fade-resistant and can include many colors. 

Popular Custom Hats Styles

Baseball Style Snapback Hats

custom baseball cap

The baseball style ball cap is the most popular hat style for embroidery. The snapback closure allows it to be “one size fit all” (OSFA). It can be 5 panel or 6 panel style. 

There are a few different styles of closure:

  • Velcro: hook and loop velcro is very easy to adjust, comfortable wear.
  • Strap & buckle: a more polished look and allows for very fine adjustments.
  • Plastic snap: can be color matched to the hat, easy to adjust and least expensive.

Dad Hats

custom dad hatDad hats are a forever popular style: it is easy, comfortable, and worn by everyone. For that reason, it makes great custom hats with personalization.

Dad hats come from the traditional snapback hats worn by baseball players, and has evolved into it’s own unique cultural style. A dad hat is just a simple 6-panel baseball cap with unstructured front panels and velcro / metal closures. The curved brim, relaxed fit, soft cotton fabric and vintage wash gives an effortless and relaxed vibe.  It is comfortable, laid back and looks good on everyone. 

Flexfit Hats

new era stretch capFlexfit hats are made by weaving polyurethane spandex into its sweatband for a comfortable stretch and fit. Without an adjustable closure, they  come in different sizes. People who love Flexfit hats prefer stretchable fitted hats. When ordering flexfit hats be sure to check out the sizing chart for the best fit for your audience. 

Trucker Hats

custom trucker hatTrucker hats (or trucker caps) originated in the early 1980s as a promotional giveaway item from feed stores and farming supply companies. They were less expensive, adjustable and have a high foam crown – which was the perfect place for companies like John Deere to embroider their logo. They have a breathable mesh in the back because they were given to trucker drivers and farm workers, giving it the name ‘Trucker hats’.

Today, some trucker hats will have a cotton front instead, but still have a breathable mesh. Many prefer the relaxed style of the trucker hat with the added bonus of the breathable mesh. 

Bucket Hats

bucket hatBucket hats have a wide, downward-sloping brim. They are usually made from heavy-duty cotton fabric such as denim or canvas. It was conceived in the early 1900s as a functional item worn by Irish farmers and fishermen as protection from the rain. Today, bucket hats are no longer for the outdoorsy type. Brands like Nike, Champion, Gucci  and Adidas all included this iconic hat in their collection.


custom beanie embroideryBeanies keep your head warm in the winter. They are made of different materials like cotton, polyester, fleece or wool. folded cuff. Beanies can have a folded cuff, and sometimes have embellishments like tassels or pom-poms.  They are also sometimes called skull caps, skit hats. There are also different fits in beanies, from slouchy, loose to snug to the head.

Beanies are popular with schools, universities, sport teams and fashion brands.

What are the decoration methods for custom hats?

Embroidery on Custom Hats

embroidery machineEmbroidery is the stitching of the logo onto a piece of garment. Your  logo is first converted to a digital image comprised of stitches and then assigned color threads, a process that is called digitizing. Then the hat is placed onto the embroidery machine, where the design is stitched out by the needles. Embroidery can be done on a variety of apparel items, such as jackets, sweatshirts, bags. You can learn more about our embroidery process here

Embroidery is the most popular option for custom hats decoration. It is fade and scratch resistant, it also gives a high quality look to the brand. There are a few different embroidery possibilities on a hat, from front, back, and side. 

How to pick colors for embroidery hat?

Normally brand colors they are noted in Pantone Color System (PMS colors), then we will match them to thread colors. Note we will always match them as close as possible but they may not be an exact match.

embroidery logo sample
An example of well embroidered logo

What are some limitations to embroidered logos?

Small Text: Since design is stitched, small text is not recommended. Minimum text height should be at least 1/4″ for clarity.

Thin lines: Due to the nature of embroidery, thin lines will not come out smooth. 

Gradient: Design with gradually changing colors, shadows are challenging to re-create with embroidery. 

In conclusion, the best embroidery logos have simple details, and consist of solid colors. We always make suggestions on how to modify complicated designs for embroidery!

Read more about promotional products imprint methods

Heat Transfer on Hats

heat transfer on trucker hatIf your logo does not quite work with embroidery, and you’d rather not modify it, there is still a way! Heat transfer on custom hats are becoming very popular – they are great with designs with many intricate details, or in full color. Trucker hats with foam top are almost always printed in heat transfers. 

Patches, labels on Hats

Grey Wool Hat Snapback with woven patch
Flexfit wool snapback hat with woven patch
leather patch hat

Patches create a whole new look on hats. They can be embroidered or woven. Leather patches look great on trucker hats too. Keep in mind that when you are designing for a patch, the imprint area is a little bit smaller than the physical patch. Keep the design simple as small details will not show well.

About the Author

Shirley Ho

Shirley is the co-founder of Garuda Promo and Branding Solutions. With a background in print production and graphic design, she specializes in promotional products marketing, creating end-products that aligns with her client's marketing goals and brand strategy.

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