Hat embroidery guide
Hats are the most common thing people search "embroidery near me" for. Battle Born Clothing stitches hats every week and makes laser-engraved leather patch hats in-house. Here is how to plan a hat order.
Pick the hat
| Hat | Style | Blank | 12-47 | 80+ |
|---|---|---|---|---|
| Richardson 112 | Mid-profile trucker, snapback | $13.50 | $20.50 | $18.50 |
| YP Classics 6606 | Retro trucker, snapback | $11.10 | $18.10 | $16.10 |
| Flexfit 6277 | Stretch-fit twill | Quoted per job | +$7.00 embroidery | +$5.00 embroidery |
| Sportsman SP12 | Cuffed beanie | $5.60 | $12.60 | $10.60 |
Pick the decoration
Flat embroidery
The standard. Cap embroidery is $13.00 (1-11), $7.00 (12-47), $6.50 (48-59), $5.50 (60-79), $5.00 (80+).
3D puff
Raised foam under the thread. Bold, simple logos only. Quoted per design.
Leather patch
Laser engraved on our 80-watt CO2 laser and heat-bonded. $8.00 per patch at 1-23 down to $4.00 at 192+. Sewn adds $4 to $6. A Richardson 112 with a patch is $21.00 at 24 and $18.50 at 144.
Logo size on a hat
Hat fronts are curved and have a center seam on most 6-panel caps. A front logo is usually about 2 to 2.5 inches tall and up to about 4.5 inches wide, depending on the hat. We size it on the proof. Thin script and tiny text are the usual problems.
Side and back logos
A side or back mark is a second location at the same tier. Fitted caps like the Flexfit 6277 have a closed back that stitches cleanly.
Ordering tips
- Snapbacks and beanies need no sizes.
- Fitted caps need a size count.
- Mix hat colors freely; the tier counts the whole order.
- Customer-supplied hats, including Melin, are $2 per item handling plus embroidery.
Bulk hat programs on our main site: https://battlebornclothing.com/pages/custom-embroidered-hats-bulk and leather patch hats: https://battlebornclothing.com/pages/custom-leather-patch-hats
A worked hat order
A landscaping company wants 48 hats: 24 Richardson 112 with a front logo and 24 YP Classics 6606 with a leather patch. The embroidered hats are their own 24-47 cap tier: $13.50 + $7.00 = $20.50 each, 24 x $20.50 = $492.00, plus $18.99 cap digitizing. The patch hats are 24-47 on the patch scale: $11.10 + $7.50 = $18.60, 24 x $18.60 = $446.40. Total $957.39 before shipping.
Structured vs unstructured
Structured caps like the Richardson 112 and Flexfit 6277 have a stiff front that holds a logo flat and works well for 3D puff. Unstructured dad hats collapse a little at the front, so logos sit softer and puff is not recommended. Beanies take small cuff logos only.
Common hat problems we fix on the proof
- Logo too wide for the front panels
- Text too thin for thread
- Too many colors for a small mark
- A center seam running through a key letter
What to send for a hat quote
- Logo file (vector if you have it)
- Hat style and color, or the look you want
- Quantity per color
- Front only, or side and back too
- Embroidery, puff or leather patch
- Your in-hands date and ship-to state
No sizes are needed for snapbacks or beanies. We reply with the all-in price per hat, the stitch count and a proof, usually starting the same business day. Standard turnaround is 28 days from proof approval, plus ground shipping.
One more tip: order a few extra hats. Snapbacks fit almost everyone, so spares go to new hires, customers or the next event, and a reorder of a handful later prices at the 1-11 tier.
Questions
What is the most popular hat to embroider?
In our shop, the Richardson 112.
Embroidery or leather patch?
Embroidery for bold color logos, leather patch for a rugged look and fine detail. Patches get cheaper faster at volume.