What Hat Sizes Sell the Most? A Guide for Baseball Cap Brands

If you’re running a cap brand in 2026, sizing is not just a technical detail—it’s the difference between repeat sales and returned orders.

The best-selling hat sizes in 2026 are 7-1/4 and 7-3/8 for men, and 7 to 7-1/8 for women. For adjustable styles like snapbacks and dad hats, Medium-Large is the most purchased size across platforms.

You can have the coolest design, the best packaging, and the fastest shipping… but if the hat doesn’t fit, your customer won’t wear it. And they probably won’t come back.

On the other hand, get the sizing right, and you’ve got:

• A customer who wears the cap regularly
• Lower return rates
• Better reviews
• Repeat business

The Hat Sizes That Sell the Most (U.S. Market)

Here’s what’s moving fast for fitted caps:

For Men:

• 7-1/4 (22.75 inches)
• 7-3/8 (23 inches)
• 7-1/2 (close behind)

For Women:

• 7
• 7-1/8
• Or Medium-Large adjustable styles, which are very common on the market

These numbers line up with sizing data from top brands like New Era, whose fitted caps follow a similar pattern for both men and women.

Snapbacks, dad hats, strapbacks—they all tend to land in the Medium-Large range. It’s the go-to for “one-size-fits-most” designs.

What’s Selling on Amazon, Etsy, and Brand Sites

Amazon

• Top Size: Medium-Large
• Style: Snapbacks, sports caps
• Trend: Fast shipping + comfort-focused sizing

Etsy

• Top Size: One-size (fits M-L)
• Style: Custom embroidered dad hats
• Trend: Gifts, personalization

Shopify / Brand Stores

• Top Size: 7-3/8 fitted or M-L adjustable
• Style: Performance golf hats, limited drops
• Trend: Direct-to-consumer focus, quality fit

Pro tip: Always mention the size range in your product name or description. It helps search and keeps expectations clear.

Sizing Isn’t Global—Here’s What Changes by Country

Hat sizing isn’t universal. Different regions use different systems, often mixing inches, centimeters, and lettered sizes. You can see these variations across the fashion world on sites like Wikipedia.

For global brands, it’s best to show inch + cm sizes on product pages and labels.

Don’t Overlook Kids’ Caps—They Actually Sell

Here’s a quick sizing guide:

Toddlers (2–4 years):

• Head size: 50–52 cm
• Hat size: 6-1/4 to 6-1/2
• Style: Velcro or elastic hats

Kids (5–10 years):

• Head size: 52–54 cm
• Hat size: 6-1/2 to 6-3/4
• Style: Snapbacks, low crown caps

Youth sizes bring in new customers—and loyal ones.

JoinTop Helps Brands Get Sizing Right

At JoinTop, we help cap brands get their sizing, fit, and production aligned.

We produce in China, Vietnam, and Bangladesh, support custom fits, and follow international standards like OEKO-TEX®, SEDEX, and BSCI.

Quick Sizing Wins for Cap Brands

1. Focus on top-selling sizes (7-1/4, 7-3/8, M-L)
2. Offer clear size info in both inches and centimeters
3. Add a youth size range
4. Use sizing keywords in listings
5. Partner with a supplier who understands real sizing—not just production

FAQ

What is the most popular hat size in the U.S.?

The most commonly sold fitted hat sizes are 7-1/4 and 7-3/8 for men, and 7 to 7-1/8 for women.

What size is considered Medium-Large?

Medium-Large hats typically fit heads between 22.5 and 23.5 inches (57–59 cm).

Are adjustable caps more popular than fitted ones?

Yes. Adjustable caps like snapbacks and strapbacks are often preferred for their flexibility and ease of fit, especially online.

How do I choose which sizes to make?

Start with the top-selling sizes (M-L, 7-1/4, 7-3/8), and adjust based on your market or platform. If in doubt, Medium-Large is usually safest.

Ready to Make Hats That Actually Fit?

Tired of guessing what sizes your customers want?

Let’s take the guesswork out. Fill out the form below, or tell us what you’re working on. We’ll reply fast with real recommendations and help you move forward with confidence.