Custom Hat and Cap Manufacturer
Nevear makes custom caps and hats for clothing brands, teams and businesses, from a first run of 50 pieces per style to bulk orders of around 50,000 pieces in a single shipment.
A cap has more parts than it looks: crown, panels, brim, closure and trims. Here is what to specify so your hats come back exactly as designed.
- Minimum order
- Typically 50 pieces per style
- Styles
- Dad hats, snapbacks, trucker caps, bucket hats and more
- Branding
- Flat or 3D embroidery, patches, prints
- Lead time
- Samples 2–3 weeks; bulk 3–4 weeks from order
Hat styles you can order
- Dad hats: unstructured six-panel caps with a low profile and curved brim.
- Structured baseball caps with a firm front.
- Snapbacks: a flat brim and an adjustable snap closure.
- Trucker caps: a foam or cotton front with a mesh back.
- Five-panel and camp caps.
- Bucket hats.
- Fedoras and wide-brim hats.
Materials
| Material | Character | Common uses |
|---|---|---|
| Cotton twill | Durable and easy to embroider | Dad hats, baseball caps |
| Brushed or washed cotton | Soft, lived-in feel | Vintage-style dad hats |
| Polyester or nylon | Light and quick-drying | Performance and running caps |
| Wool blend | Structured and warm | Fitted and snapback caps |
| Corduroy | Textured, seasonal look | Fashion caps, bucket hats |
| Mesh | Breathable | Trucker cap backs |
| Felt | Holds a shaped crown and brim | Fedoras and wide-brim hats |
Parts of a cap to specify
- Crown: structured, with a stiff front lining, or unstructured; and its profile, high, mid or low.
- Panels: five or six.
- Brim: flat or curved, and the color of the underside.
- Closure: snapback, strapback with a metal buckle or leather strap, hook-and-loop, or fitted sizes.
- Sweatband and inside taping, which can carry your branding.
- Eyelets and top button, matched or in a contrast color.
Branding on hats
- Flat embroidery, the classic for front logos.
- 3D puff embroidery, raised and bold; cleanest on structured fronts.
- Woven, leather, PVC or rubber patches.
- Screen printing for flat, graphic designs.
- Side and back embroidery, plus printed inside tape and your own labels.
Keep front logos within the front panels and allow for the curve of the crown; very fine detail does not stitch well at small sizes.
Minimums, samples and pricing
Our minimum is typically 50 pieces per style. The exact minimum depends on the style, materials and decoration and is confirmed in your quote. Each extra color adds to the order, so many brands start with one or two.
The price depends mainly on the material, how structured the cap is, the decoration (stitch count or patch type) and the quantity. Read what MOQ means, or see how our pricing works.
Tech pack checklist for hats
- Style: panels, profile, structured or unstructured
- Material and color for each part: crown, brim, underside, mesh, button, eyelets
- Closure type
- Logo files, with decoration method, size and position
- Inside tape, sweatband and labels
- Packaging that keeps the crown in shape
Frequently asked questions
What is the minimum order for custom hats?
Typically 50 pieces per style. The exact minimum depends on the style, materials and decoration, and is confirmed in your quote.
What is the difference between a dad hat and a snapback?
A dad hat is unstructured with a curved brim and a low profile, usually with a strap closure. A snapback is structured, with a flat brim and an adjustable plastic snap at the back.
Can you do 3D puff embroidery?
Yes. It suits bold logos and lettering and looks cleanest on a structured cap front.
Can the inside of the cap be branded?
Yes, with printed inside tape, a custom sweatband and your own labels.
How long does a sample take?
Samples typically take 2–3 weeks, and the sample cost is stated in your quote. Once you approve the sample, bulk orders are usually delivered 3–4 weeks from the order date, including shipping.
Ready to make your hats?
Tell us the style, fabric and quantity. We will confirm the minimum, a sample timeline and the price per piece in your quote.