Top Custom Hat Brands to Elevate Your Style Game

In the world of fashion, custom hats have become a staple accessory for those looking to add a personalized touch to their wardrobe. With an array of brands offering bespoke options, enthusiasts can tailor every detail from color and material to the design and fit, ensuring a truly unique piece. Whether you're in the market for casual caps or something more refined, the industry is flooded with top-tier brands that excel in craftsmanship and creativity. To discover the best brands for custom hats that cater to your personal style and needs, look below.

Illustration of custom hats

Best brands of custom hats in 2025

New Era

New Era Cap Company, founded in 1920, is a leading producer of custom hats, renowned for its high-quality and functional designs. As the exclusive supplier of baseball caps to Major League Baseball (MLB) since 1993, New Era produces over 65 million hats annually, with less than 2-3% manufactured in the US, primarily at their Florida plant. The company holds over 500 different licenses and has expanded its brand into various sports leagues, including the NFL, NBA, and NHL. New Era's global production is mainly based in China and Vietnam, with around 80% of shipments coming from China as of mid-2021. The company's digital transformation has led to significant growth, including a 60% year-on-year increase and a 123% rise in Black Friday sales in 2021. For more information on where New Era Caps are manufactured, follow the link.

Richardson Sports

Richardson Sports is a leading manufacturer of custom hats, celebrated for its commitment to innovation and quality over 50 years. Founded in 1970, the company has evolved into a vertically integrated designer, distributor, and manufacturer of performance and lifestyle headwear, with a revenue of $61.1 million and a workforce of 126 employees. Richardson Sports is renowned for its high-quality, customizable hats, including structured snapbacks and mesh-backed trucker hats, which are popular among businesses, sports teams, and organizations for promoting brand awareness and unity. Their products are manufactured in facilities located in Oregon, Ohio, and Texas, ensuring a wide range of styles and colors ready for immediate delivery. With a strong focus on customer service and ethical practices, Richardson Sports stands out as a leader in the headwear industry. For more information about their company and offerings, visit their official website.

Yupoong/Flexfit

Yupoong, a respected Korean family business since 1974, is renowned for its high-quality and innovative headwear, particularly the Flexfit brand, which revolutionized the industry with its stretchable cap technology introduced in 1994. With over 50 years of craftsmanship, Yupoong produces over 80 million global brand hats annually and employs over 10,000 local workers in its factories in Bangladesh and Vietnam. The Flexfit cap, made with spandex for an elastic fit, is a top choice for sports, outdoor activities, and street brands, including collaborations with global brands like Nike, FUBU, and Sean John. Yupoong's commitment to quality and comfort has made their hats a favorite among businesses and fashion enthusiasts, with custom options available for promotional products and corporate logos. The brand's innovative designs and materials ensure a comfortable fit and stylish look, making Yupoong a leader in the headwear market.

Patagonia

Patagonia is renowned as one of the best producers of custom hats, known for its commitment to ecological responsibility and high-quality products. Since 1973, the company has been a leader in organic and eco-friendly clothing, with its trucker hats made from 100% organic cotton and polyester. Patagonia's rigorous standards, such as the bluesign technologies adopted by nine of its suppliers, ensure that 30% of the total fabric used in their products meets stringent environmental criteria. The company has also reduced its supplier count by 58% to 45, enhancing its ability to manage working conditions and product quality effectively. This dedication to sustainability and quality makes Patagonia's hats a preferred choice for many consumers. For more detailed insights, explore their commitment to sustainability.

Carhartt

Carhartt, founded in 1889, is renowned for its high-quality, durable workwear and custom apparel, including custom hats that are popular among various professions and enthusiasts. The company's commitment to durability and quality is evident in its use of heavy-duty materials and rigorous manufacturing standards, such as WRAP certification for international suppliers. Carhartt's custom hats, along with other apparel, are favored by construction workers, miners, farmers, and even streetwear enthusiasts, with the brand selling around 4 million knit watch caps annually. The company's expansion into custom work uniforms has made it a go-to choice for businesses looking to brand their gear, offering a wide range of styles and customization options. With operations in the U.S., Mexico, and Europe, Carhartt employs over 3,000 associates worldwide, including 970 UFCW union members.

Legacy Athletic

Legacy Athletic, founded in 1992, is renowned for producing high-quality, vintage-inspired collegiate baseball caps and other headwear, leveraging top-notch fabrics and meticulous attention to detail. Their caps are celebrated for their perfect fit and all-American graphics, earning them the nickname "The Legacy Look." With 51-200 employees and a revenue range of $10 million to $25 million, Legacy Athletic has evolved into a comprehensive brand offering retro-inspired apparel, headwear, and home decor. Their products cater to those seeking a relaxed, casual lifestyle, combining classic designs with modern comfort and fabrics. Legacy Athletic's commitment to quality has made them a favorite among consumers looking for custom hats.

The North Face

The North Face, though primarily known for its outdoor apparel and gear, offers a range of headwear, but does not specialize in custom hats. In the fiscal year ending March 2024, The North Face reported $3.6 billion in revenue, marking a 17% increase from the previous year, with significant growth in the Asia-Pacific region at 35%, despite unfavorable currency exchange rates. This robust performance is driven by its high-quality outdoor products, including its popular Nuptse Jacket and Vectiv footwear line. The North Face markets its products globally through various channels, such as specialty outdoor stores and online platforms, and has seen a notable increase in website visits and customer loyalty. However, for consumers interested in custom hats, exploring other specialized brands might be necessary.

Nike

Nike is a leading brand in producing custom hats, offering high-quality materials and extensive customization options, including laser-cut perforations for ventilation and Dri-FIT sweatbands for comfort. The company saw a 42% growth in online sales in 2019, partly due to its focus on personalization, which includes giving users early access to new styles and using data for better recommendations.

Under Armour

Under Armour is a leading producer of high-performance athletic apparel, including custom hats, known for its innovative designs and sustainable practices. In the fiscal year ended March 31, 2024, Under Armour generated approximately $5.7 billion in global net revenues, with its apparel segment, which includes hats, accounting for about two-thirds of the company's total sales, or around $3.79 billion. The company's strong marketing strategies and partnerships with sports personalities like Stephen Curry have contributed to its success. Under Armour is also committed to sustainability, aiming for 75% of its fabrics to be made from low-shed materials by 2030. With its UA Lighthouse facility, the company continues to innovate in product design and manufacturing.

Otto Cap

Otto Cap is a leading global manufacturer of high-quality headwear, boasting a 70-year legacy in the industry. With three major distribution centers in the USA, they hold an inventory of approximately 50 million hats. Ranked among ASI's Top 40 Suppliers in 2023, Otto Cap offers a wide range of customizable hat styles, including the popular Otto Comfy Line and Otto Foam Front Trucker hats. Their products are known for their comfort, durability, and excellent customization options, making them a favorite among businesses for promotional headwear. Otto Cap's commitment to innovation and customer satisfaction has earned them a strong reputation in the market. For more information about their products, visit their official website.