Custom Hats - Design Your Own with AI

Custom hats usually mean embroidery: a setup fee, a minimum order and a stitched version of your logo that loses its fine lines. Here the design is printed, so you describe it, see it on the hat and order the number you need - one for a gift or a set for the whole crew.

Three hats

• Foam trucker hat: OTTO Cap's 39-165 - a high, structured foam front that stands up for the print, a mesh back that breathes and a plastic snap. The hat most events and brands mean by trucker.
• Dad hat: OTTO Cap's 18-253 - unstructured, low-profile cotton twill with a pre-curved visor and a hook-and-loop strap. Soft, and it sits low.
• Surf cap: AS Colour's 1114 - lightweight recycled nylon, unstructured, with a snapback and a single front panel.

Choose the hat and its color above to see it.

The trucker comes in solid White, Black, Navy or Red, or in a two-tone named front/mesh: Black/White, Navy/White, Royal/White, Kelly Green/White, Dark Green/White, Blue/White, Light Pink/White, Hot Pink/White and Red/White/Royal. Navy/White is a navy front and visor on a white mesh back. The dad hat comes in Khaki, White, Black, Navy, Royal, Red and Dark Green, and the surf cap has the widest range of the three, from White and Bone to Carolina Blue and Fire.

Printed, not stitched, on a small front

Every hat here is printed on the front panel by DTF: the design is printed on a film and heat-pressed on, for bright color and crisp edges. None of them is embroidered. That is what removes the setup fee and the minimum, and it means a logo keeps colors and detail that thread cannot.

The front of a hat is small - the trucker prints 5.5 x 2.5in, the dad hat 5 x 2in and the surf cap 4.5 x 2.35in - so a simple mark, an initial or a short line of lettering reads best. A paragraph or a detailed scene shrinks past reading.

• The trucker's foam front is one piece with no seam, so a wide logo prints across it square.
• The dad hat is six-panel, so a seam runs down the middle of the front and the print runs over it. Keep small text off the center line.

Designing one

Type what you want - "Lake crew, a small pine tree over the year, white on navy" - and you will see it on the hat. Already have a logo? Upload a PNG or SVG and place it. Then adjust by saying what is off: bigger, simpler, try it on the khaki dad hat, drop the tagline. Every revision renders on the hat and color you picked, so the mockup you approve is what gets printed.

Designing is free, and you pay when you order.

Quantities

Every hat is one size and adjustable, so an order is how many of which hat, in which color. Mix hats and colors in one order, and add shirts, mugs or totes to the same checkout with one shipment.

Printing, turnaround and care

Orders are printed by US print-on-demand partners after you check out, which is why there is no minimum and nothing sits in a warehouse.

• Production: generally up to 10 business days, plus shipping.
• Tracking: you get it when the order leaves.
• A wrong or defective print: we reprint it or refund you - send a photo within 30 days of delivery.
• Print areas: a hat has one, on the front, so there is no extra area to price.
• Care: spot clean the trucker and the dad hat with warm water, a little dish soap and a soft brush, and do not soak them; wipe the surf cap with a damp cloth.

Good hat orders

• Events and giveaways
• Brand merch and staff
• Teams, crews and coaches
• Trips, reunions and bachelor or bachelorette weekends
• Gifts

The same mark works on a t-shirt or a performance shirt, and for something to drink from, see custom mugs.

Design a custom hat →