Creating a custom hat is more than printing your logo on a blank cap. If you’re a U.S. brand owner looking for a reliable custom hat manufacturer, this guide walks you through the entire process—from concept to production to shipping.
JoinTop is a full-service private label hat manufacturer with factories in China, Vietnam, and Bangladesh. We help brands of all sizes turn creative cap designs into high-quality products, delivered globally with fast lead times.
What Is Custom Hat Manufacturing?
Custom hat manufacturing refers to the full-cycle process of producing headwear from scratch, tailored to your brand’s specifications. This includes everything from material selection and logo placement to private labeling, bulk production, and shipment.
We support fashion brands, merch creators, and wholesalers looking to produce hats that reflect their own identity—not stock caps from generic catalogs.
Step-by-Step Hat Manufacturing Process
1. You send your design
Whether it’s a sketch, a photo, or a previous product, we start with your creative direction.
2. We create a tech pack
This document outlines measurements, panels, logos, labels, fabric details, and trims.
3. You choose materials
Options include cotton twill, mesh, recycled polyester, nylon, and wool blends. Swatch books are available.
4. We sample your design
You receive a physical prototype within 5–7 working days. We revise it until approved.
5. Bulk production begins
Once the sample is confirmed, we move to large-scale production in the factory that best suits your needs.
6. Quality control inspections
All units pass through our JoinTop360™ multi-step QC system and optional third-party inspection.
7. Packaging and shipment
Your hats are packed (bulk or retail-ready) and shipped with tracking and full customs clearance if required.
Types of Custom Hats We Make
- 6-Panel Dad Caps (Unstructured)
- Snapbacks / Flat Brim Caps
- Trucker Hats (Mesh back)
- 5-Panel Camp Caps
- Bucket Hats
- Performance Hats
- Fitted Caps
Minimum order quantities start from 100 units depending on the style.
Decoration Options
- Flat Embroidery
- 3D Puff Embroidery
- Woven Labels & Patches
- Rubber/PVC Badges
- Sublimation & All-over Print
- Distressed/Vintage Washes
- Custom Inside Labels & Hang Tags
You can combine decoration methods to create unique finishes.
Pricing, MOQ and What It Costs
Starting MOQs:
- 6-Panel Dad Cap: 100 pcs
- Trucker Hat: 100 pcs
- Bucket Hat: 100 pcs
- Performance Cap: 100 pcs
Sample Price Ranges (Ex-Factory):
- Embroidered Cotton Cap (100 pcs): $3.80 – $5.50
- Mesh Trucker Cap with Patch (200 pcs): $3.50 – $4.20
- Printed Bucket Hat (150 pcs): $4.00 – $5.00
Prices vary by fabric, logo complexity, packaging, and shipping destination. Contact us for a custom quote.
Shipping and Fulfillment
- Sample Time: 7–15 working days
- Bulk Production: 15–25 working days
- Shipping to USA: 10–40 days (Air or Sea)
- DDP Option: Duties paid, door-to-door delivery
- Amazon FBA prep and 3PL support available
We manage logistics from our factories to your warehouse or fulfillment partner.
Client Feedback from U.S. Brands
“We tried Printful first, but the quality didn’t meet our standard. JoinTop gave us full control over fabric, label design, and embroidery. Our first 100-piece run sold out in two weeks.”
— Westside Merch Co., Los Angeles
“JoinTop turned a photo of a vintage 5-panel into a production-ready cap in under a month. Clear communication, solid sampling, and they nailed the fit.”
— Civic Threads, Chicago
How JoinTop Compares to Printful and TheStudio
| Feature | Unisciti a Top | Printful | TheStudio |
|---|---|---|---|
| Low MOQ (100–300 pcs) | Yes | No | Yes |
| Fully Custom Styles | Yes | No | Partial |
| Private Label Branding | Yes | No | Limited |
| Factory Direct | Yes | No | No |
| Competitive Unit Pricing | Yes (Bulk) | High | Mid |
| U.S. Brand Support | Yes | Yes | Yes |
Where Our Hat Factories Are Located
China
Ideal for high-end embroidery, complex constructions, and detailed QC.
Vietnam
Perfect for mid-volume fashion lines with fast lead times and balanced pricing.
Bangladesh
Best suited for bulk orders with basic construction at competitive cost.
We help you choose the right factory based on your budget, order size, and timeline.
Frequently Asked Questions (FAQ)
What’s the sample process like?
You’ll receive a physical production-style sample in 5–7 working days. Revisions are included.
What if my order has defects?
We offer refund or reproduction under our QC policy. All issues are resolved quickly.
Do you ship directly to Amazon or 3PL?
Yes, we support Amazon FBA labeling and packing requirements.
Do you offer sustainable hat options?
Yes. We offer recycled cotton, RPET polyester, and biodegradable trims.
Can I visit your factory?
Yes, virtual factory tours and video walkthroughs are available on request.
Request a Quote or Sample
Ready to produce your own hats? Whether you’re testing a new idea or scaling production, we’re here to help.
Request a Quote or Sample from JoinTop
We respond within 24 hours with custom solutions for your brand.
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