Fitted Hat Co.: Custom Fitted, Flexfit and Snapback Hats
Flexfit fitted caps, flat-bill snapbacks and on-field styles with 3D puff or flat embroidery, from 12 caps to 1,000+. Priced per cap, proofed before stitching, decorated by Battle Born Clothing.
- No hard minimum
- Embroidery from $5.00 per cap at 144+
- 3D puff available
- 28-day turnaround
- Ships nationwide
Fitted Hat Co. is a Battle Born Clothing brand. We embroider and patch custom fitted hats, Flexfit stretch-fit caps, snapbacks and flat bills for teams, retail brands, car clubs, gyms, bars and schools. Flexfit, Richardson, YP Classics, Zapped Headwear and New Era make the blanks; we put your logo on them. Our shop in Yerington, Nevada runs two commercial embroidery heads with Rapos thread, has made laser-engraved leather patches since 2020 on an OMTech 80-watt CO2 laser, and is an authorized decorator for Carhartt, Nike and OGIO. Every order gets a digital proof, a 28-day standard turnaround from proof approval, and a free redo if the error is ours. Flat embroidery on a cap runs $7.00 per cap at 24 pieces and $5.00 at 144+, plus the blank; 3D puff is quoted per design.
Real work from the shop
Photos from Battle Born Clothing in Yerington, Nevada — the shop that makes everything on this site.
What your order can look like
Hear it in 40 seconds
Prices, minimums and turnaround for custom fitted and snapback hats, read out loud.
Transcript
Fitted Hat Co. is a brand of Battle Born Clothing in Yerington, Nevada. We embroider Flexfit fitted caps, flat-bill snapbacks and on-field styles with flat or three-D puff embroidery, in-house. No hard minimum. Cap embroidery runs eight dollars a cap at twelve pieces and five dollars at one forty-four, on top of the blank, with a one-time digitizing fee of eighteen ninety-nine. Send artwork, a quantity, sizes and colors and you'll usually have a quote the same business day. Twenty-eight days from proof approval.
Fitted, Flexfit and snapback caps we decorate
Flexfit 6277 Wooly Combed
The classic Flexfit. Structured mid profile, curved visor, stretch band in four size ranges. The default fitted cap for teams and companies.
Blank quoted per job; embroidery from $5.00 per cap at 144+
Details →
Flexfit 5001 V-Flexfit Cotton Twill
Cotton twill Flexfit with a softer hand than the 6277. Same stretch band, mid profile, curved visor. Good for lifestyle and brewery caps.
Blank quoted per job; embroidery from $5.00 per cap at 144+
Details →Flexfit 6210 Premium Fitted
Flat-visor Flexfit with a high structured crown. The fitted-look cap for streetwear and team orders without true fitted sizing.
Blank quoted per job; embroidery from $5.00 per cap at 144+
Details →
Flexfit 6297F Pro-Baseball On-Field
The on-field cap. Performance poly/spandex, high crown, flat visor, moisture-wicking band. Built for puff team logos.
Blank quoted per job; embroidery from $5.00 per cap at 144+
Details →
Flexfit 110F Wool Blend Flat Bill Snapback
Flat bill with a wool-blend front and Flexfit's 110 flex band under a snapback. One size, premium feel.
Blank quoted per job; embroidery from $5.00 per cap at 144+
Details →
Flexfit 180 Delta
Seamless front, stain-resistant, sweat-resistant band. The cleanest canvas for a large leather patch or a wide puff logo.
Blank quoted per job; embroidery from $5.00 per cap at 144+
Details →Bulk fitted and Flexfit cap orders for teams, brands and companies
Most of our fitted-cap work is 48 to 300 caps for a team, a retail brand or a company that already knows the style number. You pick the blank and colors, send a logo, and we return a proof showing stitch count, placement and (for puff) which parts of the logo will be raised. Pricing is per cap with breaks at 24, 48, 72, 96, 120 and 144 pieces. See the full table on the pricing page.
Team and league caps (48 to 144+)
Travel ball, adult leagues and school programs usually order the Flexfit 6297F on-field cap or the Flexfit 6277 in team colors with a 3D puff front logo. Flat embroidery on the front runs $6.50 per cap at 48-71 and $5.00 at 144+ plus the blank and one $18.99 digitizing fee. 3D puff is quoted per design because foam height and stitch count change the price. Mixed sizes in one order are fine; we size-sort before packing.
Retail and streetwear drops (24 to 500)
If the cap is going on a shelf or a product page, the embroidery has to hold up next to national brands. We run Rapos thread, true-to-logo digitizing and clean backing trim. Flat-bill snapbacks like the YP Classics 6089M, Flexfit 110F and Richardson 511 take puff on the front and flat embroidery on the side or back. A laser-engraved leather patch on a flat bill is $7.50 per cap at 24-47 and $5.00 at 144+, plus the blank.
Company and crew caps (12 to 96)
Car clubs, gyms, bars and small companies order 12 to 96 caps and usually want one logo, one placement. Flat embroidery at 12-23 pieces is $8.00 per cap plus the blank; at 24-47 it is $7.00. No hard minimum. Read the cost guide for worked examples at 48 and 144.
3D puff, flat embroidery or leather patch: which one?
3D puff embroidery
Foam under the stitches raises the logo off the crown. Best for bold letters, numbers and simple shapes on structured caps. Fine detail, thin lines and small text do not puff well; we usually puff the main shape and stitch the detail flat. How 3D puff works.
Flat embroidery
The standard. Up to 6,000 stitches on the front panel, priced on the tier table. Side hits, back arch text and sleeve-style small logos are added placements, quoted per job. Flat embroidery details.
Laser-engraved leather patch
Full-grain leather engraved on our 80-watt CO2 laser and glued (or sewn, add $1.00 per cap) to the front of a flat bill or fitted cap. No digitizing fee. Patches up to about 2.5 in wide sit flat across a center seam; the seamless Flexfit 180 Delta takes larger shapes. Leather patch details.
Fitted vs Flexfit vs snapback: pick the closure first
True fitted
No closure, sized to the head (6 7/8, 7, 7 1/8 and so on). New Era fitted styles are quoted per job through SanMar. Orders need a size breakdown up front; see the sizing chart.
Flexfit stretch-fit
Elastic sweatband in two to four ranges (S/M, L/XL and so on). The Flexfit 6277, 5001 and 6210 cover most orders. Easier than true fitted because two or three sizes fit nearly everyone.
Snapback
One size, plastic snap closure, the lowest-risk choice for a group you cannot measure. Flat-bill snapbacks (6089M, 110F, Cobra) and curved-bill trucker snapbacks (Richardson 112). Our guide on fitted vs Flexfit vs snapback goes deeper.
Why order your caps from Battle Born Clothing
- Two commercial embroidery heads in our Yerington, Nevada shop (a Happy HCD2-1501 and a YunFu 15-needle) running Rapos thread, with Maggie magnetic frames for caps.
- Laser-engraved leather patches made in-house since 2020 on an OMTech 80-watt CO2 laser, glued with our heat process or sewn on request.
- No hard minimum on embroidery or leather patch. Price breaks every 24 pieces from 12 up to 144+.
- Flat cap embroidery from $5.00 per cap at 144+ (up to 6,000 stitches), plus one $18.99 digitizing fee per logo that stays on file for reorders.
- Authorized decorator for Carhartt, Nike and OGIO; blanks sourced from SanMar (Reno warehouse first) and S&S Activewear, plus Zapped Headwear as a dealer and Decky direct.
- Digital proof before production on every order, quotes usually the same business day.
- Standard 28-day turnaround from proof approval. Rush quoted per job.
- Free redo on any error that is ours.
- Ships nationwide from Nevada.
How much do custom fitted and snapback hats cost?
Decoration is priced per cap and breaks every 24 pieces. Same logo, same order: every style counts toward the same price break. The blank is added on top. Flexfit, YP Classics, Zapped and New Era blank prices are quoted per job (usually the same business day) because supplier cost and brand pricing vary by style and color; the Richardson 112 snapback is listed below as a fully priced reference. 3D puff is quoted per design. One-time fees are listed separately.
| Quantity | Blank (Flexfit 6277) | Flat embroidery | All-in embroidered | Leather patch | All-in patch |
|---|---|---|---|---|---|
| 12-23 | Quoted per job | $8.00 | Blank + $8.00 | $8.00 | Blank + $8.00 |
| 24-47 | Quoted per job | $7.00 | Blank + $7.00 | $7.50 | Blank + $7.50 |
| 48-71 | Quoted per job | $6.50 | Blank + $6.50 | $7.00 | Blank + $7.00 |
| 72-95 | Quoted per job | $6.50 | Blank + $6.50 | $6.50 | Blank + $6.50 |
| 96-119 | Quoted per job | $6.00 | Blank + $6.00 | $6.00 | Blank + $6.00 |
| 120-143 | Quoted per job | $6.00 | Blank + $6.00 | $5.50 | Blank + $5.50 |
| 144+ | Quoted per job | $5.00 | Blank + $5.00 | $5.00 | Blank + $5.00 |
How long does a fitted hat order take?
Standard turnaround is 28 days from the day you approve the digital proof. Flexfit and Richardson blanks usually arrive from SanMar Reno within a few days; the rest is queue time, digitizing, stitching and packing. Need caps for a season opener, a drop date or an event sooner than that? Put the date on the quote form and we will price a rush for your job.
Who orders custom fitted and snapback hats from us
Streetwear and retail brands
Flat-bill snapbacks and fitteds for drops and wholesale, 24 to 500.
Read more →Bars and music venues
Merch caps that pay for themselves: flat bills with puff or patch, 24 to 144.
Read more →Schools and boosters
Spirit caps, staff caps and fundraiser runs, 48 to 300, youth sizes available.
Read more →Frequently asked questions
What is the minimum order for custom fitted or snapback hats?
No hard minimum. The smallest price tier is 12-23 caps. One sample cap is possible at that tier plus the blank and digitizing.
How much do custom fitted hats cost?
Decoration is $7.00 per cap at 24-47 and $5.00 at 144+ for flat embroidery, $7.50 to $5.00 for a leather patch, plus the blank. Flexfit and New Era blanks are quoted per job; a Richardson 112 snapback is $20.00 all-in at 48. 3D puff is quoted per design.
How long does an order take?
28 days from the day you approve the digital proof. Rush is quoted per job.
Do you sell New Era hats?
We decorate New Era NE1000 and NE400 caps sourced through SanMar and quote the blank per job with New Era pricing respected. We do not list New Era blank prices.
What is the difference between fitted and Flexfit?
True fitted caps are sized to the head with no closure. Flexfit caps use an elastic band in two to four size ranges. Flexfit is easier to order for a group. See the guide on fitted vs Flexfit vs snapback.
Can you do 3D puff embroidery?
Yes, on structured caps. We quote puff per design and show a flat option beside it.
Why is 3D puff quoted per design instead of from the table?
Foam area and the dense satin stitching that covers it drive stitch count more than logo size does. Quoting from the art keeps the number accurate.
Can you put a leather patch on a flat bill?
Yes. Laser-engraved leather patches are $7.50 per cap at 24-47 and $5.00 at 144+, glued; sewn adds $1.00. The Flexfit 180 Delta's seamless front takes the largest patches.
Is there a setup or digitizing fee?
Embroidery: $18.99 once per logo, kept on file for reorders. Leather patches: no setup fee.
What artwork do you need?
Vector (AI, EPS, PDF, SVG) preferred; a 300 dpi PNG works. Send the quantity, style, colors and a size breakdown for sized caps.
Get a quote on custom fitted or snapback hats
Tell us what you need and we'll price it from real blank costs and our decoration matrix. Quotes usually go out the same business day.