A fitted hat has no closure to hide sizing errors, so every size has to be sewn to an exact head circumference. That is why most factories will not make them at low volume. We run fitted sizes from 6 7/8 to 8 on structured 6-panel blocks.
Mike Apparel manufactures custom fitted hats with structured 6-panel crowns, flat brims, buckram-fused fronts, closed backs sewn to true fitted sizes, sweatbands with size labels, and 3D puff, flat and patch embroidery. Wool-blend, twill and performance polyester fabrics. As a custom fitted 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 Acrylic-wool 80/20 melton (the classic fitted) and Cotton twill 280 GSM (twill fitted).
| Fabric | Specification | Best for |
|---|---|---|
| Acrylic-wool 80/20 melton | structured | the classic fitted |
| Cotton twill 280 GSM | 100% cotton | twill fitted |
| Performance polyester 250 GSM | 100% polyester, moisture-wicking | sports fitted |
| Corduroy | 100% cotton | corduroy fitted |
Fit options for hats
Pick a starting silhouette and we adjust from there. Blocks are graded XS to 3XL in US sizing, and size-set samples are available for brands that want to check the whole run. For a fitted hat, we usually sample the flat-brim fitted, high crown first and adjust from there.
- Flat-brim fitted, high crown
- Curved-brim fitted
- Low-crown fitted
- Stretch-fit (flex) fitted
How we build a custom hat
Construction is where a hat either earns its retail price or does not. The details below are standard on our hats; anything not listed can be specified. Start your fitted hat tech pack with this line: closed back sewn to fitted sizes 6 7/8 to 8 (or S/M, L/XL flex).
- Closed back sewn to fitted sizes 6 7/8 to 8 (or S/M, L/XL flex)
- Buckram front panels, flat brim with board
- Sweatband with printed or woven size label
- Sewn eyelets and matching top button
- Optional stretch band for flex-fit
Embellishment and wash
Every embellishment listed here is produced in our own print, embroidery and wash departments in Sialkot. Panels are decorated before assembly where placement demands it. For fitted hat decoration, 3D puff front embroidery leads, followed by side and back flat embroidery.
- 3D puff front embroidery
- Side and back flat embroidery
- Under-brim print
- Woven and PVC patches
- Custom inside taping and labels
For a method-by-method comparison on hats, read screen printing vs DTG vs embroidery.
Private label, labels 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. For fitted hat orders we recommend a woven neck label plus a printed care label as the minimum; hang tags and 59fifty style packaging are added at your choice.
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. At the low end a fitted hat in Acrylic-wool 80/20 melton with one placement lands near $6.5; at the top, Cotton twill 280 GSM with multiple placements and full packaging reaches $13.
| Quantity | Price per piece (USD) |
|---|---|
| 50–100 pieces | $6.50 – $13.00 |
| 100–300 pieces | $5.72 – $11.44 |
| 300–1,000 pieces | $5.07 – $10.14 |
| 1,000+ pieces | $4.55 – $9.10 |
Prices are FOB Sialkot; DDP shipping to the USA adds roughly $1.20–$3.50 per piece by sea or $3–$7 by air depending on weight and volume. Sampling is charged at 2–3x the bulk unit price and credited back on the bulk order. A first fitted hat run at $6.5–$13 per piece lands in the USA for about $9.5–$19 per piece by air.
Fitted Hat production timeline
The production process for a custom hat runs in five steps. Sampling takes 7–10 days; bulk takes 2–3 weeks after approval; DDP air freight to the USA takes another four to seven days. Fitted Hat samples ship with a swatch of Acrylic-wool 80/20 melton so you can compare weights before bulk.
- 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.
- Pre-production sample (7–10 days)One hat in your fabric, fit, colour and branding. Revisions until approved. Read about the sampling process.
- Approval and depositSign off the sample and size set; 50% deposit reserves fabric and the production slot.
- Bulk production (2–3 weeks)Cutting, sewing, wash, decoration, labelling, QC and packing in-house, with photo updates.
- 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.
Ready to sample a custom fitted hat? Share your artwork and quantity. We quote in 24 hours and ship a pre-production sample in 7–10 days.
Shipping hats DDP
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 New York or Chicago 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. A 50-piece fitted hat order fits in a few cartons and clears US customs as one DDP consignment with a single commercial invoice.
Frequently asked questions
What sizes do you make fitted hats in?
6 7/8, 7, 7 1/8, 7 1/4, 7 3/8, 7 1/2, 7 5/8, 7 3/4 and 8. Or a two-size flex fit with a stretch band.
What is the MOQ for fitted hats?
50 pieces per design and colour across the size run. We recommend weighting the run toward 7 1/4 to 7 1/2 for the US market.
Can you make a flex-fit version?
Yes. A stretch sweatband and elasticated back give a two-size flex fit that simplifies inventory.
What is the price of a custom fitted hat?
$6.50 to $13 per piece at 50–100 units with 3D embroidery and size labels.
Related to the fitted hat: custom hat manufacturer, custom dad hat manufacturing, custom trucker 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.