TL;DR: Most hat orders come down to two choices — the unstructured dad hat (versatile, works for almost everyone) or the structured flex-fit cap (sporty, great for athletic teams). Beyond those, beanies are huge in winter, flat bills have a specific audience, and trucker hats are more niche than they used to be. Embroidery is the standard decoration method for hats, and logos need to be simplified for the smaller space. Custom embroidered hats start around $15 and go up from there depending on brand and complexity. When in doubt, ask us — there are more options than people realize, including puff embroidery and patterned styles that can really make a hat stand out.
Walk into almost any business, sports team, or event and you'll find custom hats. They're one of our most popular decorated items at Jersey Ink — and one of the most common sources of confusion for customers who aren't sure what they're looking for.
The good news: most hat decisions come down to a few basic style choices. Once you understand those, everything else falls into place.
Here's a breakdown of the five styles we get asked about most, what makes each one different, and how to figure out which one is right for your order.
Style 1: The Dad Hat (Unstructured Baseball Cap)
The unstructured baseball cap — commonly called the dad hat — is the most versatile hat we sell. If you're not sure where to start, this is usually the answer.
What makes it "unstructured" is the construction: there's no buckram (a stiff backing material) behind the front panels, so the hat doesn't hold a rigid shape on its own. Instead, it molds to your head over time, creating that relaxed, broken-in look that's become the default for casual wear.
Dad hats typically have a low profile — meaning the front panel isn't as tall — and they're usually made from cotton twill, which gives them that soft, lived-in feel. The closure is usually a loop buckle (a strap that slides back and forth) or a velcro hook-and-loop closure.
Who it's for: Just about everyone. The dad hat works across ages, demographics, and industries in a way that most hat styles don't. It doesn't skew too masculine, too sporty, or too fashion-forward — it just works. If you're ordering for a diverse group, this is almost always the safe choice.
Our top pick: The Adams Headwear LP101 — a pigment-dyed dad hat that has been one of our all-time favorite recommendations. The pigment dyeing gives it a rich, slightly faded look right out of the bag, and it embroiders beautifully. It's the first hat I reach for when a customer asks for "something classic."
Style 2: The Structured Cap (Flex Fit)
The structured cap is the other main category — and it's the one that reads more sporty and athletic.
What makes it "structured" is that buckram backing behind the front panels, which means the hat holds its shape on its own even when you're not wearing it. It sits more upright, gives the front panel a cleaner surface for embroidery, and has a more polished, put-together look compared to the slouchy dad hat.
Structured caps tend to have a mid to high profile and usually close with a snapback or flex-fit band. Flex-fit uses a stretchy elastic band to conform to the wearer's head without any adjustment — great for teams where you want one-size-fits-most simplicity.
Who it's for: Athletic teams, sports programs, and groups with a more male-skewing audience. The structured cap has a sporty, performance-oriented look that works well for football programs, baseball teams, and organizations where that athletic aesthetic fits the brand.
Style 3: The Flat Bill / Snapback
The flat bill is a variation on the structured cap — same construction, but with a brim that stays perfectly flat rather than curved. It's a high-profile style that tends to read more urban and fashion-forward.
Here's my honest take: the flat bill has a specific audience. Not everyone loves it, and plenty of people who order flat bills end up curving the brim themselves anyway. It's more of an acquired taste than a crowd-pleaser. If you're ordering for a group and you're not sure everyone will embrace the look, I'd lean toward a curved-bill structured cap or a dad hat instead.
That said, for the right brand — a streetwear-influenced business, a youth sports team that wants that edge — the flat bill can be exactly the right call.
Style 4: The Beanie
Beanies are a completely different category from baseball caps, but they're one of our strongest sellers every winter — and they're worth including in any conversation about custom headwear.
The basic knit beanie is simple, functional, and universally wearable. We carry solid options at a really approachable price point, and they look great with either embroidery or a sewn-on patch. There's not a lot of complexity here — it's a hat people actually reach for on cold days, which means your logo is going to get worn.
Who it's for: Any fall or winter order, especially for schools, sports teams, and businesses in colder climates. If you're building out a full merch store for a sports team, a beanie at a strong price point is almost always worth adding to the lineup.
Style 5: The Trucker Hat
The trucker hat — structured front panels with a mesh back, typically a snapback closure — was everywhere in the early 2000s and has had various waves of revival since. Right now, it's not at a trend peak the way it was in its heyday, but it still has a place.
The mesh back makes the trucker hat noticeably breathable, which can be a practical consideration for outdoor and summer use. It also gives it a distinct look that some brands actively want — retro, workwear-adjacent, or just different from the standard options.
Who it's for: Customers who specifically ask for it, or brands where that aesthetic fits. We carry trucker styles, but it's not the first thing we'd suggest unless someone has a clear vision for it.
A Note on Embroidery: What to Know Before You Order
Almost all custom hats are decorated with embroidery — and there are a few things worth knowing before you send us your logo.
The standard front embroidery area is about 2.25 inches tall by 4 inches wide. The back of the cap allows up to about 3.5 inches wide. These aren't huge spaces, so logos need to work at that scale.
Where customers run into problems: Fine detail, thin lines, and small text don't translate well to embroidery — especially at hat-sized dimensions. If your logo has intricate detail that reads great on a business card or a full-front T-shirt, we'll review it and let you know if adjustments are needed. Usually we simplify on our end and send you an approval before we produce anything.
Front center is the most common location. Some customers also add a small detail above the back closure — a website, a slogan, a team motto. Side panels work for short text like sports numbers, though that space is tight (about 1 inch tall).
One thing to avoid: embroidering on the mesh panels of a trucker hat. The open weave makes it nearly impossible to get a clean result.
Want to try something different? Ask us about puff embroidery — where the design is raised off the fabric, creating a 3D effect. It works especially well with bold, thick lettering and adds a noticeable premium look without a major price jump. It's one of those upgrades that surprises people when they see it in person.
How to Figure Out Which Hat Is Right for You
When a customer isn't sure what they want, my first question is always: who are these hats for?
If it's a broad, mixed audience — a business, a nonprofit, a school event — I almost always start with the unstructured dad hat. It's the most universally flattering and the least likely to divide a group.
If it's an athletic team, I lean toward a structured flex-fit. The sporty look matches the context, and the one-size-fits-most sizing makes ordering easier.
If someone specifically wants a flat bill, we'll do it — but I'll always mention that it's more of an acquired taste, just so they've thought it through.
And if it's winter? Add a beanie. Almost no one regrets it.
What Does a Custom Hat Actually Cost?
Custom embroidered hats at Jersey Ink start around $15 each and can go up to $50 or more depending on the hat brand, the number of embroidery locations, and whether you're looking at premium names like Nike or Under Armour. The sweet spot for most orders — a quality unstructured or structured cap with front-center embroidery — lands comfortably in that $15–$25 range.
There's no one-size-fits-all minimum, so reach out and we'll walk you through options based on your quantity and budget.
Curious About More Styles?
There's a lot more out there than what we've covered here. Our supplier headwear catalog — linked below — has the full range of styles, from basic dad hats to specialty options with patterns, unique fabrics, and premium fits. If you see something you like, just ask.
View Our Supplier Headwear Catalog
Ready to order or just want to talk through options? Call us at (610) 378-7844 or email orders@jerseyink.net. We'll help you find the right hat for your group, your brand, and your budget.
Jersey Ink has been a custom apparel shop for over 20 years, specializing in screen printing, heat transfers, and embroidery for businesses, sports teams, schools, and organizations in Reading, PA and beyond.