Custom Embroidered Baseball Cap – Structured Cotton Twill
Custom Caps & Hats
- Price range
- $6.70 – $8.90 / pc
- Minimum order
- 50 pcs
- SKU
- MRB-CAP-101
Private-label caps and hats manufacturer · Sialkot, Pakistan
Custom Caps & Hats Manufacturer
Mr Balaclava manufactures custom caps and hats for brands, retailers, teams, uniform programmes and promotional buyers, under their own label. We make baseball, dad, trucker, snapback and fitted caps, bucket and boonie hats, hi-vis safari hats and camo and military caps, from 50 pieces per design and with a standard lead time of about 14 days.
Updated
- 50 pcsMinimum order
- 14 daysStandard lead time
- 100K pcsMonthly capacity
- ISO 9001Certified (Eco Jersey Limited)
- SedexMember (Eco Jersey Limited)
At a glance
Cap and hat manufacturing at a glance
The facts buyers ask about first. They apply to every cap and hat style on this page.
| Minimum order | 50 pieces per design |
|---|---|
| Samples | Made to your tech pack and approved before bulk production; samples are paid 100% in advance |
| Production lead time | Approximately 14 days as standard; the confirmed schedule depends on the product, quantity and customization and is agreed for each order |
| Cap and hat styles | Baseball, dad, six-panel and fitted caps; trucker, snapback, five-panel and visor caps; bucket, boonie and hi-vis safari hats; camo baseball caps, military-style patrol caps and camo boonie hats |
| Fabrics | Cotton twill, brushed cotton, canvas, denim, corduroy, nylon, ripstop, polyester, recycled polyester, mesh, wool blends and printed camouflage |
| Construction | Structured and unstructured crowns, foam-front and mesh panels, curved, flat and wired brims, linings, sweatbands, eyelets and chin cords |
| Sizes | Adult and kids' sizes: one-size adjustable, or sized in centimetres to your size chart; fitted caps in a size run you set |
| Branding | Flat and 3D puff embroidery, appliqué, woven, rubber and leather patches, screen and heat-transfer prints, sublimation on polyester, woven labels, printed sweatbands, hang tags and branded packaging |
| Packaging | Polybags, cartons and hat boxes; tissue and inner supports for structured and tall hats; your barcodes and labels |
| Quality and compliance | Eco Jersey Limited is ISO 9001 certified and a Sedex member; every piece inspected; test reports from a third-party lab on request |
| Shipping | Worldwide with tracking: express by DHL, FedEx or UPS in 3–6 working days, or air and sea freight for large orders |
Categories
Caps and hats we manufacture
Five categories cover the whole range. Each has its own page with the styles, fabrics, closures, branding options and typical buyers.
Categories
Baseball & Dad CapsBaseball, dad, six-panel and fitted caps in twill and performance fabrics.
Trucker & Snapback CapsMesh-back truckers, flat-peak snapbacks, five-panel caps and visors.
Bucket & Boonie HatsBucket hats, boonie hats and hi-vis safari hats in cotton, ripstop and polyester.
Camo & Military CapsCamo baseball caps, military-style patrol caps and camo boonie hats.
Popular
Popular cap requests
The six requests buyers send us most, each with its own page.
Embroidered logo capsFlat and 3D puff embroidery, patches and labels on any cap style.
Dad capsRelaxed, unstructured low-profile caps in washed cotton with small logos.
Snapback capsFlat-peak structured caps with snap closures and printed undersides.
Fitted capsCaps made in exact head sizes with a clean, snug fit.
Five-panel capsLow caps with one wide front panel, colour-blocked in nylon, twill or canvas.
Visor capsSun, sports and golf visors with embroidered or printed peaks.
Compare
Which cap or hat fits your range?
A quick guide to the styles buyers request most. The right choice depends on the wearer, the season and the price point.
| Style | Shape | Best for | Typical build |
|---|---|---|---|
| Baseball caps | Structured, curved peak | Teams, promotion, everyday | Cotton twill, buckram, strap closure |
| Dad caps | Unstructured, low, curved peak | Lifestyle and understated logos | Washed cotton, fabric strap |
| Trucker caps | Foam front, mesh back | Summer, outdoor, festivals | Foam-backed front, polyester mesh, snap |
| Snapback caps | Structured, flat peak | Streetwear, fan shops, drops | Wool blend or twill, snap closure, printed underside |
| Fitted caps | Structured, fixed sizes | Teams and collector ranges | Size run, elastic or firm sweatband |
| Five-panel caps | Low, one wide front panel | Skate, outdoor, design-led brands | Nylon or ripstop, colour-blocked, patch |
| Bucket hats | Soft, sloping brim all round | Streetwear, festivals, outdoor | Cotton twill or nylon, reversible, all-over print |
| Boonie hats | Wide flat brim, crown band, chin cord | Hiking, fishing, festivals, field work | Cotton ripstop or nylon, eyelets |
| Hi-vis safari hats | Wide brim, mesh vents, reflective band | Road crews, construction, outdoor workwear | Fluorescent polyester, reflective tape |
| Camo baseball caps | Six panels, curved peak | Hunting, outdoor, streetwear | Printed camo twill, strap closure |
| Military-style caps | Flat top, short peak | Utility fashion, outdoor, clubs | Ripstop or twill, camouflage, patch panel |
How caps and hats are made
From pattern to packed piece
Every cap and hat starts as a pattern and ends as an inspected, packed piece. Here is the route each one takes.
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Design and pattern
We turn your brief into a tech pack: crown, peak or brim, panels, colours, closure and labels. Patterns are graded to your size chart.
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Cutting and interlining
Fabric is cut to the pattern and backed with buckram, foam or fusible interlining where the style needs structure.
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Decorating
Embroidery, patches and prints are applied to the flat panels before the piece is assembled, so placement is exact.
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Sewing and assembly
Panels, peak or brim, sweatband, eyelets and closure are sewn together.
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Shaping and finishing
Caps are steamed and pressed on forms; hats are shaped and stiffened so the crown and brim keep their form.
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Inspection and packing
Each piece is checked for stitching, symmetry, logo placement and size, then packed in polybags, cartons or hat boxes to your specification.
Customization
Customize every part of your caps and hats
You choose the fabric, the shape and every detail. Our design team turns your brief into a tech pack and shows each logo and label placement before sampling starts.
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Fabric and material
Cotton twill, canvas, denim, corduroy, nylon, ripstop, mesh and printed camouflage, in your colours.
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Crown and structure
Structured or unstructured, low to high profile, five, six or eight panels, with foam or mesh where needed.
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Peak, brim and closure
Curved, flat or wired peaks and brims; buckle, slide, Velcro, snap, elastic or chin cord.
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Embroidery, patches and prints
Flat and 3D puff embroidery, woven, rubber and leather patches, screen and heat-transfer prints, sublimation on polyester panels.
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Sizes and fit
Adult and kids' sizes, one-size adjustable or fixed sizes in centimetres, made to your own size chart.
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Labels and packaging
Woven neck labels, printed sweatbands, hang tags, polybags, cartons and hat boxes with your barcodes. Mr Balaclava's name never appears on your products.
How ordering works
From brief to delivery in five steps
Every order follows the same route, whether it is a first run of 50 pieces or a repeat order for a whole season.
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Brief and quote
Tell us the style, material, sizes, quantities, branding and deadline. We reply with a quote and suggest a suitable build.
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Tech pack
We confirm every measurement, fabric, colour and logo placement in a mockup and a tech pack before sampling starts.
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Sample
We make your sample to the tech pack and adjust fit, colour and details until you approve it. Samples are paid 100% in advance.
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Bulk production
Cutting, decoration, sewing and finishing, with a standard production lead time of approximately 14 days.
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Inspection and shipping
Each piece is checked for size, colour and finish, packed to your specification and shipped with tracking.
Request a cap and hat quote See the full manufacturing process
B2B catalog
Caps and hats from our B2B catalog
Developed styles you can order with your own branding, or use as the starting point for a custom design.
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Custom Fitted Baseball Cap – Closed Back, Team Sizes
Custom Caps & Hats
- Price range
- $7.35 – $9.80 / pc
- Minimum order
- 50 pcs
- SKU
- MRB-CAP-116
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Custom Logo Trucker Cap – Foam Front & Mesh Back
Custom Caps & Hats
- Price range
- $6.70 – $8.90 / pc
- Minimum order
- 50 pcs
- SKU
- MRB-CAP-103
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Custom Snapback Cap – Flat Peak, 3D Puff Embroidery
Custom Caps & Hats
- Price range
- $6.90 – $9.20 / pc
- Minimum order
- 50 pcs
- SKU
- MRB-CAP-118
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Custom Reversible Bucket Hat – Cotton, Logo or All-Over Print
Custom Caps & Hats
- Price range
- $7.20 – $9.60 / pc
- Minimum order
- 50 pcs
- SKU
- MRB-CAP-107
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Custom Logo Boonie Hat – Cotton Ripstop, Chin Cord
Custom Caps & Hats
- Price range
- $7.15 – $9.50 / pc
- Minimum order
- 50 pcs
- SKU
- MRB-CAP-111
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Custom Camo Baseball Cap – Printed Camouflage, Your Logo
Custom Caps & Hats
- Price range
- $7.05 – $9.40 / pc
- Minimum order
- 50 pcs
- SKU
- MRB-CAP-113
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Custom Camo Trucker Cap – Mesh Back, Patch Logo
Custom Caps & Hats
- Price range
- $6.85 – $9.10 / pc
- Minimum order
- 50 pcs
- SKU
- MRB-CAP-120
Who we work with
Caps and hats for brands, teams, uniforms and events
The same factory serves very different buyers. These are the orders we see most often.
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Fashion and streetwear brands
Logo caps, colour-blocked five-panels and bucket hats in short runs, under your label from 50 pieces per design.
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Clubs, schools and teams
Team caps and fitted caps with an embroidered crest, reordered from the approved sample each season.
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Workwear, outdoor and event buyers
Hi-vis safari hats for crews, camo and military-style caps for outdoor brands, and branded visors and caps for events.
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Retail and promotional buyers
Own-label bucket hats and caps for shops, resorts and online stores, and branded caps for campaigns and giveaways.
Buyer guides
Cap and hat guides from the Journal
Background reading on cap and hat styles, fabrics and how to choose them.
Style & Trends · 9 min readCaps for Every Style: Trendy Headwear for Modern LooksExplore caps for every style! Discover trendy headwear for modern looks, perfect for every outfit and occasion.Read the guide - Style & TrendsBaseball Caps in Modern Fashion: Comfort Meets StyleExplore how Baseball Caps blend comfort and modern style, making them a timeless and versatile fashion accessory.Read the guide
Style & TrendsPanama Hats: Timeless Elegance and Cool Style for Every SeasonPanama hats: Handwoven for timeless elegance, comfort, and classic style. Explore their history, craftsmanship, varieties, and styling.Read the guide
Material Library
Fabrics for custom caps & hats
Fabrics typically used for caps & hats, with their usual weight, warmth and stretch. Full specifications are on the cotton, polyester & recycled polyester, performance fabrics and cap & hat materials fabric pages.
Polyester Interlock
A double-knit polyester with a smooth, stable face on both sides. It takes sublimation and screen prints cleanly…
Polyester Jersey
A light single-knit polyester with a smooth face. It dries fast, takes sublimation in full colour and is…
Nylon Taslan Shell
A nylon woven from air-textured yarn, which gives it a matt, slightly cotton-like face and good abrasion resistance.…
Cotton Twill (Cap Fabric)
The standard cap fabric: a cotton woven in a diagonal twill that is firm, smooth and takes embroidery…
Polyester Microfiber Knit
A fine knit made from very thin polyester filaments. It feels smooth and soft, drapes well and shows…
Polyester/Spandex Stretch Jersey (SHY Series)
Our SHY series stretch jersey: 88% polyester and 12% spandex, knitted for four-way stretch and recovery. Close-fitting, smooth,…
FAQ
Custom cap and hat manufacturing: frequently asked questions
What is the minimum order for custom caps and hats?
The minimum order is 50 pieces per design, for every cap and hat style on this page.
How long does cap and hat production take?
Standard production lead time is approximately 14 days after sample approval. Actual lead time depends on the product, quantity, customization, material availability and sampling, and the confirmed schedule is agreed for each order. Express shipping by DHL, FedEx or UPS then takes 3–6 working days.
Which cap and hat styles do you make?
Baseball, dad, trucker, snapback, fitted, five-panel and six-panel caps, visors, bucket and boonie hats, hi-vis safari hats, and camo and military-style caps. They are grouped into four categories, each with its own page above.
Which fabrics and materials can you use?
Cotton twill, brushed cotton, canvas, denim, corduroy, nylon, ripstop, polyester, recycled polyester, mesh and printed camouflage. Structured caps get buckram or foam inside, and every cap has a cotton or moisture-wicking sweatband. We confirm the fabric on the sample.
Which branding methods do you offer?
Flat embroidery, 3D puff embroidery, appliqué, woven, rubber and leather patches, screen printing, heat transfer, sublimation on polyester, woven labels, printed sweatbands and hang tags. We digitise your artwork and confirm stitch count and placement on the sample.
Can you match my brand colours?
Yes. We match fabric, thread and trim colours to your colour references or swatches, and confirm them on the sample before bulk production.
Which sizes can you make?
Adult and kids' sizes, as one-size adjustable or fixed sizes in centimetres, made to your own size chart. Fitted caps are made in the size run you set.
What is the difference between a pre-paid sample and a pre-production sample?
A pre-paid (physical) sample is a real piece you receive and check in your hands; it is paid before production, made in about 5 to 7 days and then shipped to you. A pre-production sample is free: we make it after your order and the 30 % advance payment, and you approve it on photos, videos or a video call before the bulk production starts.
Can you make caps and hats under our own label?
Yes. Everything is made under your label: neck labels, inside prints, hang tags and packaging carry your brand. Mr Balaclava's name never appears on your products.
What are the payment terms?
For bulk orders: 30% advance payment to confirm the order and begin production, 30% during production after you have reviewed the work-in-progress update, and the final 40% after the goods have passed quality control and are ready for shipment. Samples require 100% payment in advance.
Do you ship caps and hats worldwide?
Yes. Every order ships with tracking. Express delivery by DHL, FedEx or UPS takes 3–6 working days, and larger orders can travel by air or sea freight. Shipping is priced by the weight of your order: up to 100 kg it travels door to door by express courier with import duties paid by us, and heavier orders go by air cargo, or by sea cargo from 500 kg, to your nearest airport or port.