For brands in the U.S. headwear industry, choosing the right manufacturing partner is a decision that directly affects product quality, delivery time, and ultimately, brand reputation. Whether you run a streetwear label, a sportswear startup, or a corporate merchandising program, your baseball cap manufacturer must combine consistency with creativity — and the ability to scale with your needs.
Below is a detailed look at the top 10 baseball cap manufacturers based in the United States. These are companies trusted by everyone from professional leagues to independent fashion designers.
1. New Era Cap Company
New Era, headquartered in Buffalo, New York, is arguably the most well-known cap manufacturer in the world. Founded in 1920, New Era holds exclusive rights to produce on-field caps for Major League Baseball and is also an official supplier to the NFL and NBA. The company’s signature product, the 59FIFTY fitted cap, has become a cultural symbol and a global fashion staple.
Why customers choose New Era:
- Strongest brand equity in the cap industry
- Premium-grade materials and structured fit
- Deep integration with professional sports leagues
Limitations:
- Not accessible for small brands or startups
- High minimum order requirements
- Long production timelines
2. Richardson Sports
Based in Oregon, Richardson Sports has been a trusted name in headwear since 1970, specializing in performance and athletic caps. They offer a broad range of styles including structured snapbacks, trucker hats, and mid-profile fits that appeal to sports teams and promotional resellers alike.
Why customers choose Richardson:
- Trusted by youth and collegiate sports programs
- Reasonable turnaround and stable supply chain
- Wide variety of styles and sizes for different markets
Limitations:
- Limited room for highly unique custom designs
- Aimed more at performance than high fashion
3. Flexfit (Yupoong USA)
Flexfit is the American arm of Yupoong, a South Korean company known for its innovative headwear technologies. Operating out of California, Flexfit offers a wide range of ready-to-brand hats including the popular Flexfit caps with stretch bands, unstructured dad hats, and trucker styles.
Why customers choose Flexfit:
- High comfort and ergonomic fit
- Strong support for private-label programs
- High-volume consistency and factory-grade finishing
Limitations:
- Limited direct customization for small buyers
- Most production occurs overseas, with U.S. only managing logistics and service
4. Unionwear
Unionwear, based in Newark, New Jersey, is one of the few cap manufacturers that produce entirely in the United States. All products are union-made — a critical factor for clients in the political, educational, and non-profit sectors.
Why customers choose Unionwear:
- 100% made in the USA with union labor
- Customizable styles for uniforms, political gear, and more
- Excellent for institutions with domestic sourcing requirements
Limitations:
- Higher cost per unit due to U.S.-based labor
- Fewer style options compared to global competitors
5. AmeriCap USA
Located in North Carolina, AmeriCap has specialized in rugged and durable headwear since the early 1980s. Their focus is on practical designs like structured caps, visors, and military-style hats used for workwear, corporate gifting, and promotional campaigns.
Why customers choose AmeriCap:
- Durable, functional caps built for daily use
- Reliable delivery and reordering process
- Strong supplier for uniforms and industrial accounts
Limitations:
- Not suitable for high-fashion or seasonal collections
- Limited customization flexibility
6. Pukka Inc.
Pukka, headquartered in Findlay, Ohio, bridges the gap between premium lifestyle design and structured production. Originally known for golf and resort headwear, they’ve expanded into streetwear and boutique fashion labels by offering fully custom programs with elevated design options.
Why customers choose Pukka:
- High degree of design freedom
- Suitable for premium branding and resort retailers
- Strong internal design consultation and support
Limitations:
- Slightly higher price point than basic promo suppliers
- Manufacturing timelines can stretch during peak seasons
7. Cali Headwear
Cali Headwear is based in Los Angeles and serves the fashion and entertainment industries with flexible production and low minimums. They focus on private-label manufacturing for startups, influencers, artists, and niche fashion brands.
Why customers choose Cali Headwear:
- Low MOQ and fast domestic sampling
- Ideal for creative and independent brands
- West Coast proximity with responsive service
Limitations:
- Less cost-effective for high-volume production
- Style catalog may be smaller than international players
8. Graffiti Caps
Graffiti Caps operates out of El Paso, Texas, and focuses on custom caps with an urban and cultural edge. Their client base includes hip hop brands, lifestyle stores, and promotional companies that want bold, high-impact caps with fast turnaround.
Why customers choose Graffiti Caps:
- Fast design-to-sample cycles
- Unique finishes and non-standard materials
- Willingness to support low-volume, high-style runs
Limitations:
- Less suitable for formal or traditional markets
- May not match the ultra-refined finish of premium OEMs
9. The Frank Doolittle Company
With nearly a century in the business, The Frank Doolittle Company is a trusted name in promotional merchandise, including caps, uniforms, and branded gear. They serve schools, government agencies, and institutions needing high-volume, repeatable items.
Why customers choose Frank Doolittle:
- Great for repeat orders and event-based merchandise
- Streamlined logistics for large clients
- Longevity and professionalism in customer service
Limitations:
- Not aimed at high-fashion or retail-level clients
- Very limited in design innovation
10. Cap America
Cap America, based in Missouri, is a major supplier of embroidered caps and knit headwear. Their catalog is extensive and includes trucker caps, visors, fleece beanies, and more — all decorated and assembled in the U.S.
Why customers choose Cap America:
- Strong domestic distribution capabilities
- Ideal for sports, school, and corporate clients
- In-house embroidery and quick delivery
Limitations:
- Not a true full-custom manufacturer
- Offers fewer creative customizations compared to boutique factories
Where JoinTop Fits In: A Global Manufacturing Match for Modern Brands
While these U.S.-based companies each excel in their niches, many brands are now turning to global manufacturers for greater customization, flexibility, and cost-efficiency.
JoinTop is one such partner — offering a full-scale, vertically integrated manufacturing solution with owned factories in China, Vietnam, and Bangladesh. This allows us to control quality, lead times, and price — all while supporting the specific needs of U.S. brands.
Why U.S. Clients Work with JoinTop
- Low minimums — start from just 100 pieces per design
- Full creative freedom — every stitch, label, and panel is customizable
- Quick prototyping — we provide samples fast so you can launch or test before bulk
- Bilingual support — our team works fluently with English-speaking clients
- Multiple factories, one standard — we balance cost and speed with consistent quality
JoinTop serves everyone from small streetwear startups to national retailers. Clients love working with us because we deliver the agility of a boutique with the scale of a multinational.
The U.S. cap manufacturing scene is diverse, with reliable choices for nearly every kind of brand. But if your business requires design flexibility, lower production cost, and faster scale, it’s worth exploring what global manufacturers like JoinTop can offer.
We don’t replace U.S. factories — we complement them by filling the gaps they can’t easily solve. Whether you need 100 units with 3D embroidery or 50,000 caps for a national roll-out, JoinTop is ready.
Let’s build headwear that your customers are proud to wear.
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