Custom Hats

The cost of your custom hat depends on 4 factors: 1) how many hats you order, 2) the style of hat, 3) the number of locations on the hat that you decorate, and 4) the number of colors in your design (if screen printing). You can use our Quick Price page to get a quote for any hat before you begin designing.

Yes, we have a low-minimum order of 6 pieces per design.

We don't offer single hats, but do have a low-order minimum of 6 hats per design. You can achieve this minimum with one style or by mixing and matching hat styles and colors!

Yes, from 6 pieces to 60,000 pieces, BlueCotton can handle your custom hat needs. Many customers add custom designs for their team, company, school, sorority, fraternity, or special event. People love hats and they are easy to give away since you don't have to worry about size!

Our standard turnaround time for custom hats is 2 weeks. Weeks that include holidays will add time to the order. Our Rush option guarantees your custom hat order will arrive in one week!

This is a common question since both hats and patches can be embroidered. Custom embroidered hats involve sewing the design directly onto the hat. Custom embroidered patches involve sewing the design onto a separate piece of fabric, which is then either sewn or heat pressed on to the hat. With embroidered patches, the design does not come through to the inside of the hat; only the patch's outline is visible there. This method also results in a more raised design than embroidery directly on hats.

This mostly depends on your preference and the complexity of your design. The process of embroidery isn't made to show gradience in a design. Since it is done using dyed thread, the colors do not blend in the same way as you can find in screen printing or direct-to-film. This is important to note when you're submitting a design for a hat. Embroidery is best for spot colors, or colors that are clearly separated in a design.

Embroidery is best for designs comprised of spot colors, or colors that are clearly separated. Screen print is also good for spot colors, but particularly good for designs with many colors or gradience.

Digitizing is the process of turning your design into a sequence of stitches and thread changes for the embroidery machine to read. We do not charge our customers for this service.

Your embroidered logo will outlast the hat! Embroidery is very durable and looks great for a very long time.

Of course! Our entire business is decorating apparel with our customers' designs and logos through embroidery and screen printing.

We accept .png, .jpg, .jpeg, .pdf, .ai, .eps, .psd, and .tiff.

Absolutely! If you don't already have a design there are a few ways we can help. First, you can go to our Design Studio and use the AI feature to help create the design in your mind. We also have clip art and text as well as an image upload feature in the design studio to help create designs. If neither of those options works, you can always reach out to our in-house design team for help. For the best results, being able to articulate what you'd like along with various design elements or even examples for inspiration is preferred. Our designers will send you a proof within a few days for your approval or edits. Orders over 12 pieces can utilize this service for free. Orders below 12 pieces are charged $50 for design creation.

We have so many! Choose from twill dad caps, trucker hats, structured and unstructured hats, fitted hats, performance hats, high and low profile caps, bucket hats, and beanies!

Most hats are adjustable but there are some that come in sizes. These details are available for each hat on the website.

For sure! When designing online, what you see on the screen is what you'll receive in real life! The design you created is your proof. If you leave special instructions for adjusting your design or if our team sees the need to enhance it, we will send you an updated proof for approval. It is important to respond to these proofs quickly so that they do not delay the delivery of your custom hat order.

Think of us as your local shop across the country! We ship out of Bowling Green, Kentucky to all 50 states and have been doing so for 35 years! We have 130 team members here eager to serve you. Have a question? Call us and speak to a real person. In fact, you'll be able to speak to the same real person each time you call if you want!

That would be a bummer, but it can happen from time to time. If you receive your custom hat order and it's incorrect because we sent you the wrong hat, decorated the wrong location, or your design is incorrect then we will replace your order for FREE. But if you receive the order and decide you just don't like the style of hat, we're unable to accept returns.

Worried you may select the wrong hat? We get it! Contact us and we'll send you a sample before you place your order so you can be sure.