Manufacture a wide range of custom hats, including baseball caps, camp caps, bucket hats, driver hats, knit beanies and more. Suitable for clients in retail fashion, streetwear, corporate and sports license.

Custom Hats

Product Design

I. Pattern

Custom hat sourcing starts with design. Select from our collection of base headwear designs. Popular styles include unstructured 6 panel baseball cap, classic snapback, 5 panel camp cap, pro baseball fitted caps, stretch fit caps, bucket hats, and beanies. We also offer new headwear pattern development for clients who require a unique pattern when designing their custom hats.

II. Fabric

Our manufacturing partners develop and warehouse various stock fabrics for streamlined development. Clients may select from this collection, submit their own fabric for production, or develop a new fabric entirely when designing their custom hats.

III. Branding

Clients may add branding to their custom hats in a variety of ways. Conventional options include embroidery, screen print and woven labels. More advanced capabilities such as dye sublimation, injection mold, crown piping and sonic welding are also available.

IV. Tech Pack

Combine all design information and manufacturing instructions in a clear, well-organized document. Client’s may submit their own tech pack, or request PDI to assist with tech pack preparation.

Production Considerations

I. Minimums

ItemMinimum Order Quantity
Standard style288 pieces
New pattern1152 pieces
Woven Labels288 pieces
Embroidery / Print288 pieces
Additional Size288 pieces
Additional Colorway288 pieces

II. Lead Times

ProcessLead Time
New Pattern2 weeks
Custom Sample3 weeks
Main Production 4 to 10 weeks
Packaging1 to 3 days

III. Cost

QuantitySignificant impact on materials cost.
Fabric Ranges according to quality and quantity. 
Labor Varies by skill level and location of production.
DeadlineTight schedule may increase cost of production.

IV. Location of Production

Due to evolving global trade daynamics, supply chains are being redrawn at a rapid pace. Contact us to inquire about optimal sourcing locations.



Achieve professional branding with quality hang tags and other headwear packaging options.

Past Work


“Super easy to work with and outstanding commitment to quality”

MAXXIS (Corporate)

“PDI is the most professional company we have ever worked with.”

Yardbird (Food & Bev)

“Excellent product quality and outstanding customer service”

Traveler (Retail Fashion)

Get Started

I. Our Process

We begin by establishing project objectives and conclude with delivery and inspection of the final product. Each step is outlined on the Sourcing Process page.

II. Services and Fees

Our sourcing services are comprised of design preparation, factory selection, production management and delivery logistics. We collect a fee according to the size and scope of the project. For more information, please refer to the Services and Fees page.

III. Contact

To start, complete the form below or contact us through our Facebook page.