Custom 5-Panel Hat Manufacturer

The 5-panel camp cap is the skate and outdoor brand hat: a flat front panel with no centre seam, a low crown and a strap closure. The flat front is what sells it, because it takes a big woven label or print without a seam through the middle.

We manufacture custom 5-panel hats with a seamless front panel, low unstructured or semi-structured crown, flat or slightly curved brim, nylon webbing or self-fabric strap with a plastic clip or buckle, and woven labels, patches, embroidery or all-over prints. As a custom 5-panel hat manufacturer, Mike Apparel runs 50-piece minimums, samples every style before bulk and turns production in 2–3 weeks, with your labels sewn in at the factory.

Fabrics we run for hats

We hold these fabrics for hats and knit or weave others to spec. Each has a different hand, drape and shrink profile, and the sample stage exists so you can feel the difference before committing 50 pieces to it. On this product the two fabrics we quote most are Cotton twill 280 GSM (standard 5-panel) and Nylon ripstop (technical 5-panel).

5-Panel Hat fits we build

We build the pattern on one of the blocks below or from your own measurements, grade it across XS to 3XL for the US market, and confirm every size on the sample before cutting bulk. The most requested 5-panel hat block is the classic camp cap, low crown.

• Classic camp cap, low crown
• Semi-structured 5-panel
• Flat-brim 5-panel
• Packable nylon 5-panel

5-Panel Hat construction

Our default build for hats. Change any line in the tech pack; the sample confirms it. On a 5-panel hat the detail buyers notice first is the seamless front panel.

• Seamless front panel
• Low crown with soft or light buckram front
• Nylon webbing strap with plastic clip, or self-fabric with buckle
• Sewn eyelets, cotton sweatband
• Flat brim with soft board

Printing, embroidery and finishing

Print, embroidery and wash are done in-house, so the hat and its decoration ship as one finished product with one point of responsibility. On a 5-panel hat the most common request is large front woven label.

• Large front woven label
• Front embroidery
• All-over print on nylon or cotton
• Contrast panels and brim
• Side woven tabs

For a method-by-method comparison on hats, read screen printing vs DTG vs embroidery.

Labels, tags and packaging

Private label is included, not an upsell. A custom hat from Mike Apparel ships with your woven or printed neck label, size tab, care label and, if you want them, hang tags, custom poly bags and printed boxes. Send vector artwork and we produce label samples alongside the garment sample. See our private label clothing page for label types, minimums and artwork specs. A typical 5-panel hat run carries a woven main label, printed care label and hang tag; camp cap programmes often add a woven hem loop.

Custom hat price bands

Per-piece pricing for hats at each quantity band. The low end is a simpler spec (lighter fabric, one embellishment); the high end is heavyweight fabric, multiple placements and full packaging. A detailed breakdown is on our custom hat and beanie manufacturing cost. For reference, a 5-panel hat run of 50 pieces in Cotton twill 280 GSM with one embroidery and private labels sits close to the middle of the first band.

Quoted prices exclude freight; we quote DDP separately so you see the landed cost to your door. Sample fees are credited against the bulk order. For a full walkthrough of what drives the number, read our custom hat and beanie manufacturing cost. A first 5-panel hat run at $5–$10 per piece lands in the USA for about $8–$16 per piece by air.

How the order runs

How an order for hats moves through the factory, with the timing for each stage. A first 5-panel hat order usually moves from brief to delivered goods in five to six weeks.

1. Brief and quote (24 hours)Send a tech pack, sketch or reference hat with target quantity. We reply with fabric options, MOQ and per-piece pricing.
2. Pre-production sample (7–10 days)One hat in your fabric, fit, colour and branding. Revisions until approved. Read about the sampling process.
3. Approval and depositSign off the sample and size set; 50% deposit reserves fabric and the production slot.
4. Bulk production (2–3 weeks)Cutting, sewing, wash, decoration, labelling, QC and packing in-house, with photo updates.
5. QC and DDP shipping (4–7 days by air)Inspection against the approved sample, then DDP delivery with duties paid. See our full timeline guide.

Delivery to the USA and beyond

Most of our hat production ships to the United States, DDP, meaning duties, taxes and customs clearance are paid by us and included in the quote. Air freight lands in Houston or Los Angeles in four to seven days after the run ships; sea freight takes four to five weeks and costs less for larger orders. We also ship to the UK, Canada, Australia, the EU and the UAE. See streetwear manufacturing for USA brands and our DDP shipping page. 5-Panel Hat orders to the USA are usually air-freighted; a 50-piece run weighs little enough that air costs only a few dollars per piece more than sea.

Frequently asked questions

See also, for 5-panel hat programmes: custom hat manufacturer, custom fitted hat manufacturing, custom snapback hat manufacturing, custom hat and beanie manufacturing cost, custom woven labels, hang tags and packaging.

Last updated September 5, 2026 · Mike Apparel, Sialkot. Pricing and lead times reflect current factory capacity; confirm on your quote.