Promotional headwear is branded caps, hats, beanies, visors and bandanas worn by staff, customers and event crowds. Custom Gear stocks baseball and trucker caps, bucket hats, sun hats, straw hats and beanies. They are decorated with embroidery, 3D puff embroidery, patches, heat transfer or sublimation, depending on the style and your artwork.
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Promotional Custom Printed Caps & Hats
Stay cool and on-brand with custom hats and caps
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From print to stitch, laser to emboss, we brand it all. Thousands of products, endless ways to make it yours.
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Which type of promotional headwear should you choose?
Custom caps
Caps are the usual choice for uniforms, teams and giveaways. Our custom baseball caps include 6-panel styles such as the Quick-Dry Ripstop Strapback (250gsm ripstop polyester, velcro strap, black, white or navy) and the AS Colour Surf Cap (100% quick dry nylon, snapback, one size). For outdoor crews and events, trucker caps with a mesh back run cooler. The Yupoong Mid Profile Trucker 5 Panel is 35% cotton and 65% polyester, with a snapback closure and seven colours. Browse all promotional caps for more styles.
Bucket hats, sun hats and straw hats
A brim covers more of the face and neck than a cap. Branded bucket hats give a wide front and side area for a logo. The Headwear24 Microfibre Bucket Hat is a 140g/m² microfibre in sizes S (55 cm) to XL (61 cm), so a mixed team can be fitted. Sun hats add a neck flap or chin strap. The Legionnaire Hat has a neck flap, and its product page states UPF50 fabric. Printed straw hats suit beach, garden and festival events.
Beanies, visors and bandanas
For cooler months, custom beanies carry a logo through autumn and winter. The Commando Custom Full Colour Beanie is 100% polyester with an edge-to-edge sublimation print. Printed visors suit golf, tennis and running events. Bandanas and headbands cover fun runs, kitchens and sites, and neck gaiters take a full-colour print.
| Type | Best for | Usual decoration |
|---|---|---|
| Baseball cap | Uniforms, teams, giveaways | Flat or 3D puff embroidery, patches |
| Trucker cap | Outdoor crews, festivals | Embroidery, heat transfer |
| Bucket hat | Schools, clubs, summer events | Embroidery, sublimation on suitable fabrics |
| Sun hat | Outdoor work and carnivals | Embroidery, screen print |
| Beanie | Winter campaigns, staff gifts | Embroidery, sublimation on polyester |
| Visor | Golf, tennis, running events | Heat transfer, embroidery |
| Bandana, neck gaiter | Fun runs, kitchens, events | Sublimation |
How are custom caps and hats decorated?
For most caps, choose embroidery. It lasts as long as the cap, reads as a uniform rather than a giveaway, and suits cotton and polyester twill. Fine detail and tiny text do not stitch well, so simple logos work best.
- Embroidery: thread stitched into the fabric. Side and back embroidery is available as well as the front.
- 3D puff embroidery: foam under the thread raises the logo. Use it for bold, simple shapes on the front of a structured cap.
- Patches: woven, PVC or leather patches for a textured or retro look.
- Heat transfer: full-colour logos and fine detail on trucker caps and visors.
- Sublimation: the ink dyes into polyester, so beanies, bandanas and gaiters take an all-over print without cracking or peeling. It works on polyester and light colours only.
Logos on bucket hats and cotton caps can also go on by screen printing or DTF transfers, where the artwork team confirms the method suits the fabric. The method and logo size are confirmed on your free digital proof.
Ordering custom headwear: minimums, setup, proofs and timing
There is no minimum order on any product, including headwear. Each order has a one-off setup for the logo, so the price per item drops noticeably from around 10 units. Many suppliers set minimums of 25 to 100 per style, so a small club or team can order a short run here. Product pages with quantity pricing show it on the page, and your quote confirms the branded price.
You can mix colours of the same cap or hat in one order, and the whole order counts toward volume pricing. Embroidery needs the logo digitised into a stitch file. Send vector artwork (AI, EPS, SVG or vector PDF) if you have it, or ask the team to redraw a low resolution file. Every branded order gets a free digital proof showing colours, logo size and position, and nothing goes to production without your approval.
Some stocked orders can be ready the same day, and your quote confirms timing. Custom made headwear, such as sublimated beanies, is made offshore and takes longer. A longer lead time gives a better unit price, and rush costs more. Sun hats and bucket hats sell early in the warm season and beanies before winter, so order ahead of the season.
Who buys branded caps and hats, and why
A staff cap is worn on every shift, so the logo is seen by customers all day. Pair it with embroidered polo shirts for a consistent uniform. Schools and sporting clubs use bucket hats and caps because members wear them daily for months, at games and carnivals. Event organisers hand out caps and visors so the logo moves around the venue and stays on after the event. For new starters, put a cap with a printed t-shirt in a staff onboarding kit. Multi-site businesses that reorder uniforms can ask about an online store or uniform program in the enquiry form.
You must own or have permission to use the artwork you supply, especially club and sports logos. For hats worn on site, tell us the use so the team can advise on hi-vis requirements.
Get a quote for custom headwear
Pick a style, upload your logo and tell us the quantity. Use the instant enquiry form at the top of this page, or call 1300 247 766 for a quote on the spot. Our team confirms the method, sends a free proof and quotes the branded price.
Frequently asked questions
Is embroidery or print better for custom caps?
Embroidery is the better choice for most caps. It is stitched into the fabric, so it lasts as long as the cap and looks like a uniform. Choose heat transfer when the logo is full colour or has fine detail, which suits trucker caps and visors. The artwork team confirms the method on your free proof.
What is 3D puff embroidery and when should I use it?
3D puff embroidery stitches over a foam layer so the logo stands out from the cap. Use it for bold, simple shapes on the front of a structured cap, such as a block monogram. Avoid it for small text or thin lines, which cannot raise cleanly. Flat embroidery is the better option for detailed logos.
Can I get a full-colour logo on a hat or beanie?
Yes. Sublimation gives an all-over full-colour print on polyester items such as beanies, bandanas and neck gaiters. The Commando beanie page notes the ink absorbs into the knit and gives a more subdued colour. Heat transfer gives full colour on trucker caps and visors. Embroidery stays the choice when thread colours are enough.
Can you decorate the side or back of a cap?
Yes. Side and back embroidery is available as well as the front panel. Product pages offer one, two or three decoration positions, so a cap can carry a front logo, a side icon and a back web address. Each extra position is shown in the quote setup, so check you need it before adding it.
What artwork file do I need to embroider a cap?
Send vector artwork if you have it: AI, EPS, SVG or vector PDF, with fonts converted to outlines. The team digitises it into a stitch file, usually as a one-off setup. A low resolution logo from a website or email signature usually needs redrawing. Artwork is not needed to ask for a quote, and the proof shows the result.
What is the minimum order for custom caps and hats?
There is no minimum order for headwear. Each order carries a one-off logo setup, so the price per item drops noticeably from around 10 units. Many suppliers set minimums of 25 to 100 per style, so this suits a small team or club. Your quote shows the quantity breaks for the style and decoration you choose.
How long do custom caps and hats take?
Some stocked orders can be ready the same day, and your quote confirms the timing for your style and decoration. Custom made headwear is made offshore and takes longer. Rush production is available on most products, costs more and narrows the choice. A longer lead time gives a better unit price, so order early for summer.
Can I mix colours and sizes in one order?
Yes. Colours of the same cap or hat can be mixed, and the whole order counts toward volume pricing. Light colours share one dark logo version and dark colours a light one. Most caps are one size with a snapback or strap. The Headwear24 Microfibre Bucket Hat comes in S to XL, 55 to 61 cm.
Can I see a sample before I order a batch of hats?
Yes. You can see a digital mock-up before ordering, and ask for an undecorated physical sample to check fabric and fit. The sample cost is confirmed with the quote and credited back if the order goes ahead. You can also visit the Annandale showroom by arrangement to handle caps and hats.
How do I get the best price on custom headwear?
Order around 10 or more so the setup is spread across the order. Choose one decoration position, flat embroidery over 3D puff or patches, and combine styles in one order. Mixing colours under one design still counts toward volume pricing. Allowing a longer lead time lowers the unit price, and rush costs the most.