Top 5 Custom Embroidered Cap Brands and Styles

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Updated July 22, 2022

The Top 5 Most Popular Caps for Custom Embroidery

The top 5 more popular custom embroidered caps are:

1. Custom Embroidered Richardson 112 Snapback Trucker Cap

This adjustable snapback fit cap is super affordable, flatters most everyone, and features a structured six panel mid profile.

2. Custom Embroidered Legacy OFA Old Favorite Trucker Cap

The custom Legacy trucker cap is a favorite for a reason! With its comfortable fit, super soft mesh, and trademark dirty wash, this hat is the go-to of many hat wearers. 

3. Custom Embroidered Sportsman 2050 Bucket Hat

Love it our hate it, the Sportsman Bucket hat is a fan favorite for fishing and camping. Made from cotton twill, this cap features a 3 1/2-inch unstructured crown and a brim that helps keep the sun out of your eyes.

4. Custom Embroidered Yupoong 6005 Flat Bill Foam Trucker Cap

This structured high profile 5 panel cap features the statement flat bill and a crown perfect for a custom logo or graphic.

5. Custom Embroidered Flexfit 6277 Fitted Baseball Cap

This traditional style baseball cap features a pre-cured visor and a closure with special elastic band inside the hat that stretches to accommodate various head sizes. Hat panels are made from a form-fitting fabric that allows the hat to fit most heads comfortably. 

What are the differences between cap styles?

Our customers are often asking us about the difference between cap styles—which ones are the most popular and which ones look best with a custom embroidered design? Per your request, here are the ins and outs of the most popular kinds of caps so you can choose the right one for your group.

• Six Panel Caps Six panel caps are what most of us think of when we think of  “baseball caps.” New Era introduced these iconic six panel caps back in 1934 and they still make them today. Made from 6 cloth triangles (hence the name) that extend from the top of your head umbrella style, these rounded caps look great on nearly everyone. Custom embroidered logos, images and/or names on the front of the cap look great and read well. Fitted or stretch-to-fit caps will give your custom cap a more tailored look, but have the drawback of adding a sizing element to your order. For one-size-fits all custom embroidered caps, choose caps with an adjustable closure. Choose from hook and loop (Velcro®), snap, and adjustable clasp closure options. The quality of the closure greatly affects the cost, fit and perceived value of the caps. If you’re buying hats for a sports team or business team, the six-panel cap is a solid choice that will please nearly everyone.

• Five Panel Caps Five panel caps were created in the 1990s to offer customers a larger unobstructed decoration area. As the name implies, 5-panel hats are made of five fabric pieces instead of six, so there is no front seam. Five panels come in both flat brim and bent brim styles. Flat brim versions lend a more street-smart look. The trendiest flat-bill styles also have a higher front profile. Five-panel flat bill caps are more cutting-edge in terms of fashion, so if your group is young and style-conscious, choose a 5-panel cap for your custom design. Five panels are also great for embroidering larger, complex logos or designs.

• Trucker Caps Pair the five-panel-cap with a mesh back and a stiffer foam front panel, and you have for what is commonly referred to as a trucker style cap. The name “trucker cap” first took hold when farming supply companies began giving away these relatively low-cost caps to truck drivers and farmhands as a way of raising brand awareness. Today, trucker caps have become a fashion statement. Choose custom trucker hats if you are looking for both value and cutting edge style.

• Snap Backs Snap back caps come in both 5 and 6 panels styles. They fit different size heads thanks to the addition of an adjustable snap closure on the back. These caps have come back into style in a big way and can be worn either forward or backward. See my previous blog for how to wear a snap back stylishly.

Dad Hats Dad hats are typically looser fitting, six panel caps made from canvas or cotton. The current “dad hat” trend calls for a slightly curved brim. The dad hat name comes from (no brainer here) dads over the past decades who have chosen to wear comfy caps. Now it’s a fashion statement.

• Bucket Hats Usually made from cotton, this hat has both lovers and haters. Rare are those who don’t have an opinion about a bucket cap. These unstructured caps have a rounded top and a floppy brim that provides 360 degrees of shade.  It’s a utilitarian style, shielding wearers from sun and rain, and it can be rolled up and packed easily.  

Author: Amber Barz

About Post Author

Amber Barz

Amber Barz has been researching, writing, and editing website copy since 2008. She has written multiple books, magazine articles and blogs on a multitude of topics, including fashion, decorating, and graphic design. She is graduate of the University of Northern Iowa and holds a degree in communication with minors in journalism and advertising. She has worked with Broken Arrow T-Shirt Printing and Embroidery for over a decade.
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