Looking to create branded headwear for your business or event? The custom cap industry offers solutions from bulk manufacturing to small-batch personalization.
Leading custom hat manufacturers include SanMar (for embroidered styles), Yupoong (for blank wholesale), and CapBargains (for low MOQs). These companies offer various customization options from embroidery and printing to unique fabric treatments, catering to businesses, sports teams, and promotional needs.
Discover the top manufacturers for your specific requirements, whether you need thousands of branded hats or just a few dozen personalized pieces.
Top Custom Cap Manufacturers 2024
These established companies lead the industry in quality, reliability, and customization options.
Best overall custom hat makers:
- SanMar (Premium embroidery)
- Yupoong (Blank wholesale specialist)
- Headwear Unlimited (Full customization)
- Otto Cap (Fashion-forward)
- Cap America (Made in USA)
Manufacturer Comparison
| Company | Specialty | MOQ | Lead Time | Best For |
|---|---|---|---|---|
| SanMar | Embroidered | 12 | 3-5 weeks | Corporate |
| Yupoong | Blanks | 50 | 2-4 weeks | Decorators |
| Headwear | Full custom | 100 | 6-8 weeks | Brands |
| Otto | Fashion | 250 | 8-10 weeks | Retail |
| Cap America | Domestic | 144 | 4-6 weeks | Government |
Key Selection Factors
Consider:
- Decorating capabilities
- Material options
- Minimum order quantities
- Production timelines
- Compliance certifications
Private Label Hat Suppliers for Brands
Building your brand requires manufacturers offering white-label solutions.
Top private label suppliers:
- Port & Company (Basic styles)
- Flexfit (Performance focus)
- Legacy (Streetwear aesthetic)
- New Era (Authentic licensed)
- Zephyr (Outdoor technical)
Private Label Services
Typical offerings:
- Custom labels/tags
- Exclusive colors
- Unique fabric treatments
- Branded packaging
- Custom fit specifications
Cost Breakdown
Investment ranges:
- Setup fees: $500-$5,000
- Sample costs: $50-$300
- Per-unit cost: $8-$50
- Decorating: $1.50-$10
- Shipping: Varies by quantity### Private Label Services
Typical offerings:
- Custom labels/tags
- Exclusive colors
- Unique fabric treatments
- Branded packaging
- Custom fit specifications
Cost Breakdown
Investment ranges:
- Setup fees: $500-$5,000
- Sample costs: $50-$300
- Per-unit cost: $8-$50
- Decorating: $1.50-$10
- Shipping: Varies by quantity
Best Embroidery & Printing Techniques
Different decoration methods suit various design needs and budgets.
Top decoration options:
- 3D puff embroidery (raised logos)
- Laser etching (premium finish)
- Sublimation printing (full-color)
- Chenille patches (vintage look)
- Digital direct-to-garment (photorealistic)
Technique Comparison
| Method | Best For | Durability | Cost Factor |
|---|---|---|---|
| Embroidery | Logos | High | $$$ |
| Screen Print | Graphics | Medium | $$ |
| Sublimation | All-over | High | $$$ |
| Patch | Vintage | Medium | $$ |
| Laser | Minimalist | Very High | $$$$ |
Design Limitations
Technical constraints:
- Stitch count limits
- Color separations
- Underbrim restrictions
- Gradient challenges
- Fine detail reproduction
Low MOQ Custom Hat Companies
Startups and small businesses need suppliers accommodating smaller orders.
Best low minimum suppliers:
- CapBargains (MOQ 12)
- Custom Planet (MOQ 24)
- Hats.com (MOQ 36)
- LogoUp (MOQ 50)
- Total Merchandise (MOQ 72)
MOQ Comparison
| Company | Embroidery MOQ | Print MOQ | Sample Policy |
|---|---|---|---|
| CapBargains | 12 | 12 | Free virtual |
| Custom Planet | 24 | 36 | $35/sample |
| Hats.com | 36 | 48 | Credit applied |
| LogoUp | 50 | 50 | $50+ |
| Total Merch | 72 | 72 | Minimum $100 |
Cost vs Quantity Tradeoffs
Small order realities:
- Higher per-unit cost
- Limited decoration options
- Fewer color choices
- Longer relative lead times
- Less customization
Conclusion
From bulk manufacturers to low-MOQ specialists, the custom hat industry offers solutions for every need. Whether creating branded corporate gifts, retail collections, or team uniforms, selecting the right partner depends on your quantity requirements, decoration complexity, and quality expectations.
