Where can I order the best custom embroidered hats?

We may be biased, but we think you came to the right place. Have more specific questions about how to get started? Contact us.

What customization methods are available for hats?

Creating personalized hats can add a unique touch to your style or brand. Three popular methods for customizing hats are embroidery, printing, and patches, each offering distinct advantages. Embroidery is ideal for those seeking a high-end, durable finish. This technique involves stitching a design directly onto the fabric, making it perfect for simple logos or text. The textured feel and longevity make it a favorite for businesses or events that require a polished look. Printing, on the other hand, provides flexibility in design. Whether you’re aiming for intricate patterns or vibrant, full-color images, printing allows for detailed expression. Techniques such as screen printing or heat transfer enable complex, multicolored designs that stand out. Patches offer a bold and versatile alternative. Designs are created separately and then sewn or heat-pressed onto the hat. This method allows for more texture, layering, and specialty finishes like leather, woven, or PVC patches—making it a great choice for a premium, retail-ready look. All three methods can transform a standard hat into a piece that’s uniquely yours. Whether opting for the classic appeal of embroidery, the artistic flair of printing, or the standout presence of patches, you can create a custom hat that suits your needs perfectly.

How do you make a custom embroidery design?

We take your beautiful work of art, digitize it, and enter it into our software. From there, we optimize the stitching by choosing one of two types: Satin stitching (which stitches back and forth only and is used for smaller areas) or fill stitching (in which the stitching direction can be adjusted to compensate for fabric structure and pulling).

What file types can I send my design to you in?

Staple visual files like PDF, EPS, or JPEG work. If you can send in a vector art file, though, it is preferred as we can easily manipulate it if adjustments based on threading need to be made.

How many colors can my embroidered design have?

An embroidered design can have up to 15 colors, but a practical application would be 7 to 8. Even then, that's still a little high—embroidery works best when it's simple and not muddled up by an overly busy design.

Why do custom hats take longer than other pieces?

While hats may seem easier from the outside because of their smaller size, some challenges come from bulk embroidering them. Due to the nature of machine embroidery, the garment used needs to be flattened to ensure stability and consistent outputs. While certain hat types (like beanies) can easily lay flat. Generally, any baseball cap cannot be flattened without sustaining some structural damage, so the process must be slowed down to avoid any mistakes. The extra time needed is worth it, though, we promise! We want to get the highest quality apparel and embroidery out to you—and tiny adjustments to the process ensure that.

How big can my design be?

Embroidery designs are typically smaller, but if you want to go big, keep it in the range of 10 x 10, 11, or 12 inches.

How much are custom embroidered hats?

Embroidery pricing is based solely on the stitch count and the garment itself. The bigger the design, the more stitches are used. The more stitches used, the higher the price.

Can you really embroider on any hat?

For the most part, yes! The only exception that comes to mind is hats with hard brims that encompass the whole hat—like a cowboy hat—because they would be too cumbersome to stabilize on the machine, especially since they can't be flattened like standard hats.

Does the embroidery affect the feel of the hat?

Smaller designs and lettering should not affect the feel of the hat since the backing prevents direct content to the thread while creating stability. Larger designs, though, have the chance of feeling cumbersome. This is especially so on "dad" or baseball hats since designs are directly on the forehead. Keep this in mind when creating your custom embroidery design!

Why custom embroidery on hats?

As we mentioned earlier, hats are a year-round piece to many ensembles. That level of versatility is perfect for showcasing a custom design at its highest level of exposure. Whether it's a new set of hats for a little league team, a collection of visors for a park's lifeguards, or an order of beanies for a gaming event, our custom embroidery will bring your design to life.

How can I design and customize a hat for personal or business use?

Creating a personalized hat for your personal needs or business promotion is a straightforward and enjoyable process. Whether you're aiming to enhance your brand's visibility, create a uniform look, or just want a unique piece of headwear, here's how you can get started. Step 1: Select Your Hat StyleBegin by choosing the type of hat that fits your needs. There is a variety to choose from: Baseball Caps: Perfect for a sporty or casual look. Dad Hats: Stylish with a relaxed fit. Trucker Hats: Known for their mesh backs, offering a vintage vibe. Beanies: Ideal for winter wear or street style. Each type offers a different aesthetic, so pick one that aligns with your vision. Step 2: Design Your HatTo bring your vision to life, use a design tool available on many customization websites and bring your file to Real Thread. Here, you can: Upload Your Logo or Design: Choose a crisp, clear image or graphic that represents your theme. Add Text: Whether it’s a catchy phrase, team name, or business slogan, you can select fonts and sizes that complement your design. Select Colors: Match the hat and design colors to fit your brand's palette or personal preference. Step 3: Preview and AdjustOnce you upload your design, adjust the size and placement to your liking: Check for Alignment: Ensure that your logo and text are centered or as you desire. Color Balance: Confirm that the colors are vibrant and harmonize well. Size Appropriateness: Make sure all elements are appropriately scaled. Step 4: Place Your OrderOnce satisfied with the design, specify the quantity you need. Whether it’s a single hat as a sample or a bulk order for a team or business, ensure you select the correct amount. Additional TipsCustomization Platforms: Websites like Fiverr offer design services at great rates if you need help with creating artwork. Material Preferences: Consider the material for comfort and durability, especially for extended wear. Budgets and Timelines: Some services provide budget-friendly options and expedited shipping, so you can have your hats ready when you need them. By following these steps, you can easily create customized hats that meet your personal style or business branding needs, ensuring that they stand out in any setting.

Are there any minimum order requirements for different types of hats?

Yes, our minimum order is 20 hats. We also offer samples at just 1 hat so you can be comfortable with the product before purchasing 20 or more.

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A black beanie that has an embroidered design that says "fresh wata" in a smiley face.

Make every hat a party hat

Whether it’s basic text, your brand’s logo, or a loud and colorful piece of art, hats offer a unique canvas for embroidery that can be both functional and trendy. The front of the cap makes for the most natural design location, but hats also offer a lot of room for thinking outside the box and getting creative with different embroidery locations—from the side of your head to the back and beyond.

Why custom hats are always a win

Brand Visibility

Unlike other promotional items that get tucked away in drawers, hats get worn. A lot. Your custom embroidered hats become walking billboards, spreading brand awareness wherever your team goes. From construction sites to corporate events, logo caps create countless impressions without any additional marketing spend. Think about it: every coffee run, every client site visit, every industry conference becomes a brand-building opportunity.

Built for Performance

We make headwear that holds up. Our custom trucker hats handle outdoor jobsites, while our snapback hats transition seamlessly from the warehouse to client meetings. Every style is chosen for durability first, style second: though you definitely get both. These aren't flimsy promotional throwaway items, but quality pieces that reflect well on your brand for years to come.

Employee Pride & Team Unity

There's something special about seeing your whole crew wearing matching company hats. It builds pride, creates instant team recognition, and gives everyone that "we're in this together" feeling. From embroidered hats for your sales team to promotional hats for a trade show, quality headwear creates connections that go beyond just looking professional.

A white hat with a black brim, embroidered with an orange W and P

The Real Thread Difference

Getting custom hats right involves more than slapping a logo on fabric. Color matching, thread selection, and placement precision: all of these details determine whether your promotional hats look professional or amateur. We work with your existing brand guidelines to ensure every custom embroidered hat maintains the exact colors and proportions your brand requires.

Our design team helps optimize your artwork for embroidery, suggesting adjustments that improve both appearance and durability. Sometimes that means simplifying fine details, other times it's about choosing thread colors that pop against your chosen hat fabric. The goal is always the same: custom hats that make your brand look its absolute best.

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