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Last updated: January 2026
This directory lists 58 hat manufacturers across the United States, from bespoke artisans specializing in hand-blocked felt hats and intricate cut & sew designs to large-scale producers of performance athletic caps and high-volume promotional headwear.
Buyers turn to these manufacturers to solve a myriad of production challenges, ensuring their final product meets exacting specifications. This includes achieving consistent brim curvature and buckram stiffness across thousands of units, mastering complex embellishment techniques like 3D puff embroidery or precise dye sublimation, and navigating the nuances of different panel constructions to match specific aesthetic and functional requirements. They seek partners who can maintain high quality control over every detail, from fabric sourcing to final finishing, often for diverse end-uses from fashion to industrial safety.
The hat manufacturing landscape includes distinct supplier types. Some specialize in knitted beanies and winter headwear, excelling in yarn selection and gauge control. Others are cut & sew powerhouses, expert in constructing intricate multi-panel caps, visors, and bucket hats from various woven fabrics. There are also niche players focusing on luxury or specialty materials like leather or exotic felts, offering bespoke crafting and meticulous hand-finishing, often catering to lower-volume, high-value orders.
58 companies nationwide
Based in White Plains, NY, 7 Bros Apparel specializes in custom embroidered hats and team apparel. They produce custom baseball jerseys, arm sleeves, and hoodies in small batches, offering a full design and printing process. The company works directly with sports teams, businesses, schools, and charities.
American Hat Makers, based in Emory, TX, operates a factory producing over 200 styles of wholesale hats. The company manufactures premium hats and headwear, offering selections for men and women. All products are proudly made in the USA.
Based in Los Angeles, CA, Argus Apparel manufactures custom hats for private label brands. The company produces a variety of styles including snapbacks, trucker hats, baseball caps, beanies, and bucket hats. They focus on delivering premium quality headwear for their clients.
Based in Grand Haven, MI, Authentic Manufacturing Co. manufactures custom wholesale products, including hats, from scratch. They provide cut and sew services for brands, governments, and organizations, operating ISO 14001 certified factories in the U.S. The company emphasizes carbon neutral practices and offers guaranteed low pricing.
Based in Adamstown, PA, Bollman Hat Company is an employee-owned manufacturer, designing and producing quality hats since 1868. They offer private label manufacturing services and wholesale their extensive brand portfolio to commercial customers, providing comprehensive hat production and craftsmanship.
BrandCowboy specializes in custom-built caps and apparel through its Cut + Sew program. Serving the Western, Agriculture, and Outdoor industries, they design one-of-a-kind merchandise, allowing customers to rebuild classic styles or create new ones.
Based in Des Moines, IA, Broken Arrow Wear offers custom apparel services, specializing in USA-made custom baseball caps, dad caps, mesh caps, and beanies. Their 75,000 sq ft facility handles in-house printing and embroidery for a wide range of apparel products. They provide customization for groups and teams with no minimums and free shipping.
Based in South El Monte, CA, California Custom Caps manufactures American-quality custom caps. They offer in-house design, a wide range of styles, and use premium materials. Services include custom and stock programs, private labeling, and various embroidery options with 30 years of experience.
Cali Headwear is a US-based manufacturer of custom hats, located in Carson, CA. They offer a diverse range of styles, including 6-panel, trucker, and bucket hats. The company provides customization services such as embroidery, appliques, and digital printing on both made-in-USA and imported blanks.
CAPTUER HEADWEAR provides private label custom headwear manufacturing for brands, shops, and artists. They specialize in bespoke hats with no house branding, including custom trucker hats, premium cotton strapbacks, and beanies. Capabilities cover diverse materials, styles, and features like pinch fronts and faux fur poms.
Based in Garland, TX, Classic Cap & Embroidery is a US-based manufacturer specializing in headwear. They produce wholesale hats, custom snapbacks, dad hats, and blanks for customization. The company also offers exquisite embroidery services, manufacturing caps since 1928.
Based in San Francisco, CA, Designing A Difference Sewing House is a full-service sewing contractor and manufacturer. They specialize in design development, pattern making, sample sewing, and production for custom corporate swag. Services include embroidery and manufacturing wholesale apparel, interior soft goods, and hats.
Based in Gardena, CA, Direct Caps USA is a wholesale hat manufacturer providing a wide array of headwear. With over 25 years of development, they offer fully custom programs directly from their factory, including snapbacks, trucker caps, and bucket hats at bulk prices.
Dorfman Milano is an American headwear company manufacturing handmade hats since 1921. They operate factories in the United States, producing a wide range of hats for wholesale and retail. Services include private label manufacturing and embroidery, providing quality headwear for various seasons.
Based in Vernon, CA, DTLA Print provides custom branded apparel services, including hats, t-shirts, hoodies, and more. The company specializes in custom trucker hats with embroidery and printing, utilizing eco-friendly, high-quality materials for commercial clients.
Based in Milwaukee, WI, Wisconsin Knitwear is a family-owned business specializing in the manufacturing of custom knit hats and beanies. The company produces its products in the USA and is recognized in the textile industry for its high-quality offerings and craftsmanship.
Based in Bend, OR, Monterey Company specializes in custom product manufacturing, creating branded headwear and hats for events, brands, and teams. They offer unique custom hats in various styles, colors, and sizes. The company also produces custom patches, apparel, medals, and other branded merchandise.
MVA Design & Supply specializes in bespoke cut and sew manufacturing for custom apparel and headwear. Based in California, the company offers services including graphic design, screen printing, embroidery, and sewing, leveraging 17 years of expertise for commercial clients.
Outdoor Cap Company, based in Bentonville, AR, specializes in supplying blank and decorated caps and headwear. The company caters to thousands of U.S. businesses, offering comprehensive solutions for promotional products and custom headwear designs.
Based in Pace, FL, PG Hat Company is a family-owned business specializing in custom made-to-order leather patch and full-color twill fabric hats. All patchwork is crafted and sewn in-house from full hides or fabric, ensuring lasting quality. They provide no minimums, bulk discounts, and flat rate shipping.
Based in Vernon, CA, Reach Headwear is a manufacturer specializing in custom hats and beanies. They provide a trusted partnership for brands needing quality custom headwear at any scale, offering fully customizable options including various shapes, fabrics, closures, and embellishments.
Based in San Leandro, CA, San Francisco Hat Company designs and crafts a diverse range of hats, including handwoven Panamas, expedition Riverz, and fine felts. Operating from its California studio, the company manufactures both functional and beautiful headwear, offering wholesale options to businesses.
Based in Los Angeles, CA, Seam Apparel is a custom hat manufacturer specializing in private label and wholesale production. The company produces USA-made hats, including baseball caps, trucker hats, and snapbacks, offering comprehensive cut-and-sew manufacturing solutions.
Foremost Hat specializes in wholesale blank and custom hats, offering various styles and customization options like embroidery, patches, and prints. Operating from Industry, CA, the company utilizes five global factories to provide competitive wholesale pricing, flexible ordering with no minimums, and quick turnaround times. They also focus on sustainable hats made from recycled and organic fabrics.
Based in Burlington, VT, Skida LLC manufactures a range of headwear and accessories, including beanies and balaclavas, designed for active lifestyles. The company provides wholesale custom logowear services, producing unique collections and collaborations for various businesses and teams, such as the U.S. Ski & Snowboard Team.
Based in Hilliard, OH, Steve Apparel provides comprehensive apparel manufacturing services for brands. They specialize in activewear, sportswear, and T-shirt production, utilizing cut and sew techniques and all-over sublimation printing. The company offers custom headwear, including various hat types, managing the process from sampling to final production.
Based in Oceanside, CA, The Sauce Suppliers provides premium custom-made apparel, headwear, and accessories for influential brands. As a global supply company with US and Australian teams, they offer factory-direct manufacturing, streamlined development, and ethically compliant production. They also provide comprehensive trend reports.
Based in Newark, NJ, Unionwear specializes in the custom manufacturing of ballcaps. All products are 100% union made in America, offering clients high-quality, affordable headwear. They accommodate large quantity orders, ensuring businesses can broaden their impact with custom-designed hats.
Based in Ridgewood, NY, Winner Caps MFG. Company has been a USA hat manufacturer since 1994. This family-owned business specializes in private label service, offering custom pattern creation, fabric sourcing, and embroidery. They work with brand owners to bring hat designs to reality, providing quality products and dedicated service.
Based in Los Angeles, CA, Yes We Print specializes in custom hat manufacturing, offering high-quality embroidered and printed hat options. The company provides rush services, no minimum orders, and a price match guarantee for personalized apparel. They also offer same-day custom apparel printing.
Zapped Headwear specializes in creating premium custom hats for businesses, offering decoration options such as embroidery, custom leather patches, custom rubber patches, and silicon heat transfers. The company provides both custom and blank hats at affordable wholesale prices, with quantity pricing available for larger commercial orders.
Based in Philadelphia, PA, Apliiq offers brand-first print-on-demand services specializing in custom hats and apparel. They provide over 175 hat options, including professional branding with embroidery, woven labels, and patches. Apliiq focuses on creating retail-ready clothing for businesses.
Based in Mesa, AZ, Branded Bills specializes in manufacturing and personalizing a wide range of custom headwear styles. They offer wholesale services for businesses seeking snapbacks, truckers, fitted hats, beanies, and performance gear, all produced in their US facilities.
Based in Los Angeles, Brero is a cut and sew cap manufacturer offering comprehensive services for custom caps. They provide precision production, embroidery, sublimation, and fabric sourcing. Rooted in nearly a century of American manufacturing tradition, Brero produces high-quality headwear for established labels and emerging brands.
Based in Raleigh, NC, Custom Patch Hats, LLC specializes in manufacturing premium, custom, USA-made hats and caps for brands. They offer high-quality, union-made headwear, enabling clients to add their logo for effective brand representation and brand building.
Based in Calimesa, CA, Dekni Creations Inc. specializes in custom hat manufacturing and decoration. They design and customize private label hats and beanies, offering bulk and wholesale custom embroidered and leather patch headwear. All products are made or decorated in-house in the USA for businesses and brands.
Based in New York, NY, Gold Headwear is a custom headwear manufacturer of premium, 100% customizable products. They specialize in various styles like snapbacks, 5-panel camps, and baseball caps. The company offers full customization services, enabling clients to create unique headwear with custom logos and designs.
HatLaunch provides in-house custom hat manufacturing and decoration services, specializing in 2D embroidery, leather, and PVC patches. They create detailed mockups and stitch logos onto various hat styles, including beanies. All production is performed using commercial embroidery machines directly in the USA.
HATSEMB specializes in custom embroidered hats, offering a wide selection of over 100 hat styles, including popular Richardson 112 and Flexfit caps. Customers can upload their logos for customization with no minimum order requirements. The company provides a rapid 72-hour turnaround for production and shipping.
Pacific Headwear specializes in custom headwear solutions, offering an extensive selection of caps for teams and organizations. The company provides comprehensive customization services, including embroidery, patches, and custom colors. They support clients with specific lead times and facilitate sample orders for various headwear styles.
Based in Orange County, California, nbrhd designs and prints custom trucker hats, offering a wide range of designs and color combinations. They provide personalized hats for events, schools, sports teams, and corporate branding, serving both individual and wholesale accounts. The company offers custom artwork assistance with no minimum order requirements.
Based in Ontario, CA, OTTO CAP manufactures headwear, serving clients for over 70 years. The company provides domestic decoration services with a low 24-piece minimum, ensuring quality and reliability for various custom projects. Additionally, OTTO CAP offers overseas customization services for orders starting at 72 pieces.
Resistol manufactures a wide selection of USA-made western-style hats, including both felt and straw varieties. Renowned for quality and durability, their hats are crafted with a commitment to the traditions of the American West. Resistol supplies consumers and authorized retailers.
Sandlot Goods provides custom hat manufacturing services, designing, cutting, and sewing hats in the USA. They offer a complete custom hat experience with low minimum quantity requirements and private label capabilities for businesses and teams. Their American-made hats are built to last.
SNAG Collective specializes in made-to-order custom snapbacks, allowing customers to create personalized designs using premium blanks. They also offer curated vintage apparel and cut & sew creations, complementing their custom embroidery services for a diverse range of apparel.
Threadbird offers custom hat printing and design services, empowering brands to create unique headwear. They provide creative freedom for designing bespoke hats, focusing on quality and customization for businesses. Their programs support various branding needs for custom apparel.
Weld Mfg specializes in custom hat manufacturing, allowing clients to add logos to ready-made hats or design fully custom caps from scratch. They also offer custom cut-and-sew sweatshirts and personalized socks, providing well-made, vintage-look apparel for adults and kids.
Based in Bowie, TX, American Hat Company manufactures a range of hats, including straw and felt styles. Their products are double-lacquered and double-pressed, providing enhanced durability and resistance to various elements.
Based in Enfield, NC, AmeriCap manufactures 100% custom-made baseball caps and hats in the U.S.A. since 1989. The company offers complete customization, from shape and style to color and closures, using high-quality materials for organizations and events.
Based in Los Angeles, CA, Baron Hats has over 50 years of experience manufacturing custom hats for the entertainment industry. They create handmade hats for movies, TV shows, commercials, and music videos, worn by numerous artists. The company also offers hat cleaning and restoration services.
Based in Fredericktown, MO, Cap America specializes in USA Made headwear and accessories. They manufacture a wide selection of knit scarves, knit beanies, and fleece beanies for qualified B2B customers. Offering diverse colors and styles, the company focuses on producing quality knit and fleece products in their US facilities.
Based in Madison Heights, MI, Graffiti Caps is a hat manufacturer specializing in cutting, sewing, and assembling caps in the USA. The company utilizes both domestic and high-quality imported fabrics for its production, offering a direct manufacturing solution for various headwear needs.
Based in Newark, NJ, Serratelli Hat Company is a hat manufacturer with a family legacy dating back to 1878. They meticulously craft each hat by hand, upholding generations of dedication to quality craftsmanship. All products are proudly made in the U.S.A.
Based in Parma, Ohio, The Beanie Factory is an American-made manufacturer specializing in custom knit beanies, knit caps, and winter hats. They produce high-performance headwear in-house, offering comprehensive services including free setup, design assistance, and digital mockups for business clients.
Legacy Knitting specializes in custom beanie manufacturing for various brands, offering USA-made, high-quality products. The company is also a USA-based manufacturer of premium custom socks, including golf socks, providing durable knitwear collections for businesses.
Based in Los Angeles, CA, RCSLA is a full-service apparel manufacturing and sewing house. The company specializes in delivering custom hats, prioritizing craftsmanship and quality. Serving both emerging and established designers worldwide, RCSLA offers comprehensive services including fabric sourcing, samples, pattern making, and production.
Small Batch Hats specializes in made-to-order custom patch hats, allowing clients to select hat styles, leather, and patch designs. They produce custom headwear for orders ranging from six hats to 600, serving various commercial and business needs.
Michael Hat Farming Co manufactures a diverse range of stylish and functional headwear. The company emphasizes sustainable farming practices in its production process, creating various types of headwear products. They are dedicated to producing quality headwear using environmentally conscious methods.
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Structured hats use internal stiffeners like buckram in the front panels to maintain shape, often associated with traditional baseball caps. Unstructured hats lack this support, resulting in a softer, more relaxed fit that conforms to the wearer's head. Choose structured for a sharp, classic look or promotional durability; opt for unstructured for a vintage, casual, or comfortable "broken-in" feel. Your brand aesthetic and target demographic should guide this decision.
Each embellishment technique has distinct cost and timeline implications. Flat embroidery is common and relatively quick, but 3D puff embroidery, intricate patch applications (like woven, PVC, or leather patches), or complex dye sublimation often require specialized machinery, more setup time, and can significantly increase both unit cost and overall lead time. Discuss your desired effect with the manufacturer early to understand the full impact.
MOQs for custom hats typically range from 100-500 units, but this varies significantly based on the manufacturer's capabilities, complexity of the design, chosen materials, and embellishment techniques. Smaller, artisan shops might offer lower MOQs (e.g., 50 units) but often at a higher per-unit cost, while larger factories generally require higher volumes to achieve cost efficiencies for cut & sew production. Always clarify MOQs upfront.
A proto sample is your initial prototype to confirm the overall design, fit, and general construction. The pre-production sample (PPS) is a final, production-ready sample, made with actual materials and embellishments, sent for your approval before bulk production begins. Approving the PPS is crucial as it signifies your acceptance of the final product, including details like brim curvature and color accuracy, and is your last chance for revisions without incurring significant costs or delays.
Achieving consistent brim curvature requires precise manufacturing processes and quality control. Inquire about the manufacturer's brim molding techniques and their quality assurance protocols, such as using specific jigs or gauges for checking curvature. Ensure they provide a pre-production sample (PPS) with the exact desired curvature for your approval, and confirm their ability to replicate this consistently throughout the entire production run.
Yes, specific certifications can be crucial depending on your target market and materials. OEKO-TEX Standard 100 ensures textiles are free from harmful substances, vital for any product worn close to the skin. CPSIA compliance is legally required for all children's products (including hats) sold in the United States, regulating lead content and other safety aspects. For sustainable products, GOTS (organic cotton) or GRS (recycled materials) validate your environmental claims. Always verify required certifications based on your product and market.