Five decisions define your cap
Every style we build comes down to the same five variables. Lock these and the rest — colours, packaging, freight — falls into place.
| Decision | Options we run | What it changes |
|---|---|---|
| Construction | 5-panel · 6-panel · structured · unstructured | Panel count sets the crown silhouette. Structured panels hold a large flat logo; unstructured ones drape. |
| Crown height | Mid crown · high crown | High crowns take taller front logos. Mid crowns suit classic proportions. |
| Brim | Pre-curved · flat · bend-to-shape | Curved is the default on baseball and dad caps. Snapbacks ship flat. |
| Closure | Plastic snap · hook & loop · metal buckle · elastic | Snap suits one-size merch. Hook & loop is the softest for kids and event runs. |
| Logo craft | Embroidery · 3D puff · patches · printing · woven labels · foil | Craft decides minimum size, colour count and how the logo reads from three metres away. |
What a cap is actually made of
The parts below are what you are paying for. Most quotes that look cheap have cut something from this list — thinner buckram, a skipped inner tape, a plastic closure where the sample showed metal.
| Part | What it is | Where it matters | |
|---|---|---|---|
 | Crown panels | Front, side and back panels joined at the seams | Panel count and interlining decide whether the crown holds its shape |
 | Brim | Upper and lower brim with a stiffener between | Brim width and stitching rows are visible from across a room |
 | Embroidered logo zone | The front panel surface your logo sits on | A structured panel keeps a large logo flat and readable |
 | Sweatband and inner tape | The band inside the crown plus the tape over the seams | The only part your customer touches every time they wear it |
 | Closure | Snap, hook & loop, buckle or elastic at the back | Sets the fit range and the look from behind |
 | Rear panel | Back arch and rear branding area | The most overlooked logo position on any cap |
Where the money goes
Four variables move a unit price more than anything else. Understanding them is how you get a quote that survives contact with the factory.
- Quantity — the single biggest lever. Fixed costs (cutting, digitising, setup) spread across the batch.
- Craft — flat embroidery is the baseline. 3D puff, patches and all-over print each add cost and handling.
- Fabric — cotton twill is the baseline. Wool blends, corduroy and technical fabrics cost more per metre.
- Trims and closure — metal buckles, woven labels and custom inner tape are small line items that add up.
A 6-panel baseball cap starts at $6.80 per piece at our 25-piece minimum, and drops to $3.03 at 1,000+ pieces. The full published tier table lives in our pricing guide.
See the price tier table, 25 to 1,000+ pieces
How an order runs
Four stages, no mystery. We give you the same sequence whether you order 25 caps or 25,000.
| Stage | What happens | Timing |
|---|---|---|
| 1 · Mockup and quote | Send a style and a logo file. We return a quote the same day and a free digital mockup. | Same day |
| 2 · Sampling | A real sample is produced and sent with photos and video before you commit. | 7–10 working days |
| 3 · Bulk production | Production starts after you approve the sample, with daily progress updates. | 15–20 days |
| 4 · QC and dispatch | AQL 1.5 inspection, individual packing, then your choice of courier or sea freight. | On dispatch |
The mistakes we see most
These four come up in almost every first order, and each one costs either money or a season.
- Choosing craft before fabric. A 12-colour logo that works on cotton twill will smear on mesh or sink into wool.
- Sizing the artwork too small. Under 3 cm wide, small details disappear in thread.
- Skipping the sample. Sampling is the cheapest stage to change your mind.
- Forgetting the inside. Sweatband labels and inner tape are the details that make a cap feel expensive.
FAQ
Quick answers
25 pieces per style, in a single colour — colours are not mixed inside one minimum, and each style is counted separately. A second colourway is its own 25 pcs, and the artwork setup is shared.
Samples take 7–10 working days after artwork approval and usually reach you within a week by express courier. Bulk production takes 15–20 days from sample approval, depending on quantity and craft.
Yes. Digitising and the first mockup are free, and the pre-production sample is on us with your production order. The 25-piece minimum is there so a first run costs less than a dinner out.