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Custom hats are a great way to promote your brand, bring your team together, or create awesome giveaways. They’re stylish, useful, and people actually wear them, which means more eyes on your logo.
But when it’s time to make your custom hats, one big question comes up: Where should you get them made? And how much will it cost?
Well, the answer depends on your design, quantity, and quality choices.
Let’s check what goes into the price and how to make the most out of your custom hat budget.
Key Takeaways –
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So, How Much Does It Cost To Make A Hat?
Well, we can only speak for our own custom hat options here at The Apparel Pro. We work hard to keep our prices competitive while still giving you great quality.
The exact price depends on the hat style you choose and how many you order. We offer different brands, including NEW ERA. Here’s a quick look at our current pricing for custom hats:
1. New Era Headwear
Premium headwear includes caps, beanies, and bucket hats:
Style Description | MSRP (Blank Hat) |
Snapback & Flat Bill Caps (e.g. Stretch Mesh) | $11.49 – $12.99 |
Performance & Ballistic Caps | $12.49 – $13.99 |
Bucket Hats (Enum: Hex Bucket Hat) | $15.99 |
Beanies (Ribbed, Sideline, Knit) | $10.99 – $12.49 |
2. Outdoor Cap & YuPoong (Private‑Label)
Durable and versatile caps. It is ideal for branding and bulk orders:
Style Description | MSRP |
YuPoong Wool‑Blend Flat Bill Snapback | $9.26 |
Outdoor Cap Weathered Cotton Twill Cap | $10.18 – $10.91 |
Outdoor Cap Mossy Oak Blaze Cap | $9.57 |
3. DRI DUCK (Private‑Label)
Rugged outdoor hats suitable for utility and branding:
Style Description | MSRP |
Wildlife Series Mallard Cap | $12.76 |
Why Do These Brands Matter?
- New Era:
It delivers premium brand recognition, a lot of variety, and style—perfect for standout merch.
- YuPoong & Outdoor Cap:
Cost-effective blanks with reliable quality.
- DRI DUCK:
Great for outdoor and adventure themes, emphasizing rugged utility.
What Affects the Price of Custom Hats?
If you’re on a budget, it’s helpful to know what things can make custom hats more or less expensive.
That way, you can make choices that fit your price range. Here are some of the main things that affect the cost:
How is the hat decorated?
There are different ways to personalize a hat, and the method you choose can raise or lower the price.
- Embroidery is one of the most popular options. It gives the hat a strong, professional look. However, it can be more expensive because it takes time and effort to do.
- Patches are another option. These can be sewn onto the hat and can be either embroidered or woven. The price depends on how big and detailed the patch is.
- Screen Printing is commonly used for clothing like t-shirts or socks, and sometimes used for hats. It’s usually cheaper and works well for simple, bold designs. But, it’s not as long-lasting as embroidery or patches.
Hat Style and Material
The type of hat and what it’s made from also affects the price. Hats that are more premium—like Flexfit, structured snapbacks, or ones made with special fabrics (like wool or sweat-wicking materials)—will usually cost more than basic cotton caps.
Think about how the hat will be used. If it’s for sports or outdoor use, you might need certain materials that perform better, which often means a higher price.
Still not sure how much custom hats cost? Here are some popular styles you can look into:
- Custom trucker hats
- Custom baseball hats
- Custom golf hats
- Custom dad hats
- Custom beanies
How Many Hats Do You Order?
The number of hats you order has a big impact on the price. The more hats you buy, the less you pay for each one—it’s that simple.
Most companies (including The Apparel Pro) have a minimum order amount. With us, you can order even 1 hat.
Note: Ordering just 25 hats will cost more per hat than if you ordered 500.
That’s because making hats in larger batches saves us money, and we pass those savings on to you.
Design Complexity
Not all custom hat designs cost the same. If your design has a lot of colors, fine details, or 3D embroidery, it takes more work and materials to make—so it’ll cost more.
Also, if your logo needs to be placed very precisely or you’re combining different decoration styles (like embroidery and patches), that adds to the price. On the other hand, a simple hat with a small logo on the front will be more budget-friendly.
How Fast Do You Need It?
We usually finish custom hat orders a few weeks after the design is approved. But if you need your order rushed, it will cost extra. To save money, try to plan ahead and order early.
Here is what most people think about the factors affecting the price of custom hats –
What makes specific hats more valuable than others?
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Why High-Quality Custom Hats Are Worth the Price?
Even the cheaper custom hats can feel pricey at first, especially for small businesses, sports teams, or event organizers. It might be tempting to go for the lowest price, but spending a bit more for better quality is usually the smarter choice. Here’s why:
They Last a Long Time
Well-made hats—whether decorated with embroidery, patches, or made from quality materials—hold up over time. They stay comfortable, look good, and survive lots of wear and washing.
Cheaper hats, on the other hand, can fade, fall apart, or lose their shape quickly. That’s a problem for two reasons: first, it can make your brand look unprofessional.
Second, if people stop wearing the hat, you’re missing out on the free promotion that comes from someone showing off your logo.
Better Branding and a Professional Look
When you add your logo to custom gear, it should look sharp and professional. Clean logos, neat stitching, and good-quality materials show that you care about the details. This helps people take your brand seriously and builds trust.
This is really important for businesses, but also great for teams and events—it helps everyone feel proud and more connected.
Comfort That People Will Actually Wear
You want the hats you make to be comfortable. If they’re not, people won’t wear them—and that defeats the purpose!
Soft fabrics like cotton blends or moisture-wicking materials might cost more, but they feel better and are more likely to be worn often.
Saving Money in the Long Run
Yes, high-quality hats can cost more upfront. But they last longer and look better, so you don’t need to replace them as often. Plus, they leave a much better impression than cheap, low-quality options.
Think of them as an investment—you get more value over time. And with The Apparel Pro, you don’t have to choose between quality and price. You can have both.
To Wrap Up
Whether you want embroidered designs or custom patches, we make sure your hats look amazing, with no surprise fees.
We’re proud of every order we send out and back it with a satisfaction guarantee.
With fast turnaround times and a team that truly cares, this is the best place to create your custom hats—quick, easy, and done right.
Frequently Asked Questions
Q1: How much does it cost to make a custom hat?
A1: The cost depends on how many hats you order and how detailed your design is. If you’re just making one hat, it can be more expensive, especially with embroidery. But if you order more hats at once, the price per hat goes down.
Q2: What’s the average profit margin for hats?
A2: Most hat businesses make about a 40% profit on each hat, and some make up to 60%. The exact profit depends on things like the cost of materials, marketing, and other business expenses.
Q3: Where can I design my own hats?
A3: You can design your own custom hat right here at The Apparel Pro—we make it easy for you!