Custom Hats 101: Where and How to Get Yours Made

Custom hats are one of the most versatile and impactful pieces of branded apparel you can create.. Whether you’re building merch for your brand, unifying your team, or creating a killer giveaway item, a well-made hat can tie everything together. But when it comes time to actually make them, one big question always comes up: Where’s the best place to make custom hats?

The answer depends on a few things—like your design, quantity, and quality expectations. In this guide, we’ll break down your options (from local print shops to premium custom printers), help you understand what to look for, and share why the right hat partner makes all the difference.

Let’s find the perfect fit.

What to Consider Before Making Custom Hats 

Before you get the ball rolling on submitting an order for custom hats, there are a few key things to consider to make sure the supplier you’re working with aligns with what you’re looking for. 

1. Purpose- Are you planning on using these for events, giveaways, uniforms or a high quality addition to your clothing line? If you’re excited about these hats lasting for years to come, or making a big impact with your staff, make sure your vendor is keen on the details. 

2. Quantity- Are you looking for a smaller batch of high quality hats or a big bulk order where time is of the essence and price really moves the needle? Some vendors have a huge embroidery capacity and can do large bulk runs very efficiently, while others are more well suited for smaller, high quality runs.

3. Design needs- Are you looking for embroidery, patches, printed hats…or maybe even a mix of styles? Not all suppliers offer each method, and some specialize in specific ones. 

4. Turnaround Time and Budget- How fast do you need your hats delivered, and what’s your ideal price point? Speed and price can vary greatly depending where you choose to have your hats made. 

Where to Make Custom Hats: Your Options

1. Local Print Shops 

Pros: In-person service, supporting local businesses. 

Cons: Limited styles or capabilities, possibly higher pricing.

2. Online Custom Hat Makers 

Pros: Easy interface, fast ordering, lots of styles. Examples: Printful, Printify, Zazzle, Custom Ink, and RushOrderTees

Cons: Less customization, may use low-quality printing or heat transfers. Generally more focused on getting orders in and out than on super high-quality results. 

3. Premium Custom Apparel Printers 

Pros: Expert embroidery, premium hat selection, better materials, real customer support. Ideal for businesses, events, and clothing brands. Example: Real Thread :) 

Cons: May have higher pricing, minimums or lead times depending on service.

What Sets a Great Custom Hat Maker Apart?

Quality, quality, quality. There can be a big difference in custom hats, especially when it comes to the quality of the embroidery. If hats are done too quickly or without refined detail the results can end up looking sloppy and unprofessional. 

A great custom hat maker will be knowledgeable about the entire process, focus on the details and still keep up a good pace. Plus, they’ll be able to provide best in class customer service, design support (especially on the do’s and don'ts of embroidery designs) and transparency on pricing and timelines. You definitely don’t want to end up with a product you’re not excited to wear and share!

FAQs About Making Custom Hats 

How much do custom hats cost? 

The cost will depend on the blank hat you’d like to use, the number of locations you want to customize, and the size and complexity of your design(s).

What’s the turnaround time? 

At Real Thread, our standard turnaround time is right around 2 weeks. Some vendors will be faster (but you might be sacrificing a quality result in the process.) 

Can I order just one hat? 

Yes! In fact, we recommend ordering a sample of your design to make sure you have everything just like before you move forward with a bulk order of 20 or more hats.

Do I need to have a design ready?

We’ll typically need a design to get your order rolling, but we’re happy to help you nail the details or support you if you need a little push to the finish line.

Start Your Custom Hat Order with Confidence

Finding the right place to make custom hats comes down to what matters most to you—quality, style, support, or speed. Whether you’re creating merch, outfitting your team, or designing something unforgettable for your community, the right partner makes all the difference.

At Real Thread, we combine expert embroidery, premium products, and a genuinely helpful team to bring your vision to life—without the headaches. So if you’re ready to elevate your hats (and your brand), we’re here to help you do it right.