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Articles on designing your own custom merch, growing your brand, and managing manufacturing as a small business.

How to Design & Create Custom Sports Hats and Caps Online

Sports hats are super popular year-round. People love wearing them as sports spectators, on the field, while watching a big game at home, and even on a regular Tuesday to cover up a bad hair day. Sports hats help people rep their love for a particular team or sport and help fans instantly identify one another, forging a powerful connection.

What’s more, the sports merchandise market is positively massive, estimated at $9.3 billion in 2020 alone. It’s an enormous market any small business owner would be lucky to capture a small sliver of… and while it’s competitive, there’s plenty of room for an underdog to win some major business.

Nowadays, creating a line of custom sports hats and caps online is easier than ever. With the help of The/Studio’s handy product creation tool, large companies and small-scale creators alike can create custom snapback hats, dad hats, baseball hats, beanies, trucker hats, five-panel hats, and other sports hats right from their computer – no DIY or previous design experience required.

What’s more, there’s plenty of room for creativity – though existing images such as logos, mascots, and player numbers make a great jumping-off point to draw from, custom sports hats lend themselves to a world of design possibilities.

Designing and creating custom sports hats can prove to be very lucrative for your business as long as you go about it the right way.

In this article, you’ll learn everything you need to know about designing your own line of custom sports hats, including:

  • Why design custom sports hats?
  • Is designing custom sports hats a good idea for your business?
  • How to design custom sports hats

Get ready –  creating custom hats could be huge for your small business! Learn how to design and create custom sports hats and caps online so you can take your biz to the next level.

custom printed hats online the studio

Why design custom sports hats?

It’s no secret that the sports merchandise market is a large one. But sports hats alone are hugely popular as well. Over 40 million baseball caps are sold each year, accounting for over 80% of all hat styles in the United States. Long story short, plenty of people out there are in the market for a quality, well-designed baseball cap.

Beyond the market, sports hats have a unique power to bring people together and foster a sense of community. By representing a team or sport, they unite people with common interests and add a sense of homegrown charm to any team uniform or outfit. 

Sports hats are also an excellent choice to complement other sports products you may carry in your store. They go along well with custom sports lanyards, patches, pins, keychains, socks, and beyond.


While there’s a large market for custom sports hats repping major teams, many local businesses also see success creating custom sports hats and caps for local minor league or college teams. They’re a great idea for teams that have a committed fan base, even if it’s a relatively small one.

Of course, the best reason to introduce custom sports hats – or any product, really – into your business is the potential for profit. Custom sports hats are in-demand products with attractive margins available at an affordable cost, with certain custom styles starting at just $3.63 apiece depending on order quantity.

custom trucker hats the studio

Is designing custom sports hats a good idea for your business?

Designing custom sports hats could be a very strategic and lucrative idea for your business. However, it’s not necessarily the best idea for every retail store or business model. 

Before you decide to invest your time and money into creating a line of custom sports hats, make sure you have a clear idea of who will purchase them and what they look for in a custom product. Ask yourself these questions to figure out whether designing custom sports hats and caps is a good idea for your business;

  • How many custom hats do I need?

First off, be sure you have a good idea of how many sports hats you’d like to place an order for. Many custom hat manufacturers set fixed minimum order quantities of at least 100 or more. The/Studio has no minimum order quantities, but it offers significant savings for larger orders. You can still place a custom hat order of any size, from 5 to 50,000 – just be prepared to pay a little more if you place a small order.

  • How much can you afford to spend?

Consider how much your customers would be willing to pay for your hats – and make sure that price offers good enough margins compared to the cost of manufacturing your custom hats. If you’re not sure how much your hats might be able to sell for, check out comparable hat prices in your area or online.

  • What will your hats be used for?

Think about it: will your customers wear these hats while they’re playing baseball? Will they be worn by fans in an indoor venue? Will your customers wear these hats as part of their everyday outfits? Getting a clear idea of what your hats may be used for can help you not only determine whether your customers will get much use out of them but also what type of custom hat you should make. 

  • How will hats fit with everything else you sell?
    Will your custom sports hats fill out your product line nicely, or will they look as though they belong in a totally different store? If you already sell sports merchandise such as custom sports socks, lanyards, keychains, pins, or patches, custom sports caps might be a no-brainer – but if you primarily sell home decor, you might want to rethink this decision. (Thinking of introducing other custom sports products in your store at the same time? Browse all of the custom products you could create with The/Studio here.)


  • Do your customers even want custom hats?

This is an important one! While custom sports hats are a popular option throughout the U.S., you’ve got to make sure your existing customer base is actually in the market for custom hats. If you know your audience well enough to answer that Q, great. If you’d like to make sure… ask them! Send out a survey to your customers to figure out whether they’d be interested in custom sports hats. You could even create mockups of a few designs and ask people to vote on their favorites. 


If custom hats don’t seem to be a popular option, you could also create custom sports socks, custom sports patches, custom sports pins, or custom sports stickers instead using The/Studio’s same handy product creation tool.

design your own hat online

How to Design & Create Custom Sports Hats and Caps Online

Have a clearer picture of whether you ought to create custom sports hats and what type of custom sports caps you should create? Awesome! You’re ready to start the product creation process. Again, if you partner with a company like The/Studio, it’s possible to complete this entire process online, from customizing the specs of your hat to designing your cap to bringing your vision to life. Here’s how to design and create custom sports hats and caps online:

1. Find a manufacturer

Don’t worry – we don’t expect you to knit any beanies or sew any snapbacks yourself! Instead, partner with a great custom hat manufacturer to take most tasks off your plate. Since the end result of your custom hats ultimately depends a lot on the quality of materials used and the manufacturing techniques, you’ll want to make sure you partner with a reputable company.

Keep an eye out for a custom sports hats manufacturer who provides:

  • Great customization options
  • A variety of custom hat styles
  • Competitive pricing
  • Free domestic shipping
  • Fabulous customer service
  • Free design services with every order
  • Fast turnaround time
  • Low minimum order quantities
  • 100% satisfaction guaranteed

That last one’s especially important – that way, you’ll be able to order with confidence that you’ll be happy with your order – and that if you’re not, your manufacturer will make things right. The/Studio is a great option that checks all the boxes. It allows you to create top-quality custom hats online with a straightforward DIY product creation tool. Click here to start the hat creation process, select your order quantity, and let the fun begin! 

2. Choose the hat type

Next up, figure out what type of hat you’d like to create. With The/Studio, you can make custom snapback hats, baseball hats, dad hats, five-panel hats, fitted hats, trucker hats, beanies, and everything in between.

The type of hat you want to make will help you determine what to choose for all sorts of customization options, including style, material, profile shape, bill shape, and more. 

Learn more about the 6 most popular hat types and how to use The/Studio’s product creation tool to make them here.

3. Customize your hat

Your basic hat type will help you determine certain customization options – but even beyond that, The/Studio allows you to customize all sorts of aspects of your sports hats, including:

  • Style – choose from 5-panel, 5-panel with pinch-tuck style, or 6-panel
  • Material – choose from 100% cotton twill, cotton/poly twill, corduroy, poly mesh, full color printed twill, 70% acrylic/30% wool blend, faux suede, faux leather, faux satin, or screen printed twill
  • Profile shape – Choose from a structured, unstructured, or foam structure build
  • Bill shape – Choose a curved or flat bill
  • Cap closure – Choose from a plastic snapback, velcro strap, custom-fitted, metal tri-glide, metal bronze buckle, plastic tri-glide, custom metal buckle, faux leather strap with custom buckle, one size fits most, or plastic snapback with custom logo closure.
  • Packaging – Choose to add a patch, hangtag, or label to your custom hat.
  • Profile height – Choose a low, medium, or high profile.
  • Exterior – Choose to add woven eyelets, woven top button, custom bill stitching, nylon mesh back panels, sandwich bill, metal eyelets, metal top button, or custom piping details to your hat’s exterior.
  • Interior – Choose to add a solid-colored sweatband, a custom printed sweatband, a mesh sweatband, an elastic sweatband, solid-colored taping, or custom-printed taping to your hat’s interior.
  • Embroidery – Choose to add embroidery in one or more locations.
  • Screen-printing – Choose to add screen printing in one or multiple colors on your hat.

4. Design your hats

Once you’ve customized all the specs, you’re ready to upload your hat design to the platform. If you’ve already come up with the perfect design you’d like embroidered or printed on the front or back of your cap, just upload the file and add a few notes about how you’d like your design to be carried out. 

If you’re not much for design, that’s perfectly fine! Submit any doodles or inspirational images you have (including other hats you admire, team logo or mascot designs, color schemes, etc) along with notes describing what you’d like to see, and our design team will take all the design work on. (Professional design services are included free with every order!)4. Approve a mockup

Next up, just sit tight! Our design and production teams will take whatever sketches or notes you’ve provided and turn them into a fleshed-out custom sports hat. Then, they’ll send a mockup of your hat to you for review. This may be delivered as a physical prototype in the mail or through detailed photos.

If we’ve succeeded in bringing your vision to life, fabulous! Give us the go-ahead and we’ll make sure all of your other hats look just like that. But if you see anything you’d like changed, just let us know and we’ll tweak whatever needs tweaking. (Free of charge!)

5. Sell your custom hats

We’re almost there! Once you’ve submitted your approval, we’ll manufacture the rest of your custom sports hat order and send them straight to you with free domestic U.S. shipping. Then, all that’s left for you to do is start selling your line of sports hats to your customers! 

Ready to start designing your own line of sports hats? Start the process here.




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