Embroidery on bucket hats, dad hats and 5-panel caps
Battle Born Clothing embroiders headwear on two commercial single-head machines, a Happy HCD2-1501 and a YunFu 15-needle, with Rapos thread and Maggie magnetic frames. Unstructured crowns get a firm backing and a cap frame. Every order gets a digital proof before a needle moves.
Embroidery price per hat
| Quantity | Per hat |
|---|---|
| 12-23 | $8.00 |
| 24-47 | $7.00 |
| 48-71 | $6.50 |
| 72-95 | $6.50 |
| 96-119 | $6.00 |
| 120-143 | $6.00 |
| 144+ | $5.00 |
Add the blank. Bucket, dad and 5-panel blanks on this site are quoted per job; as a reference with a known blank, a Richardson 112 trucker ($13.50) is $20.00 all-in at 48 and $18.50 at 144. Digitizing is $18.99 once per design and is not charged on reorders. Over 6,000 stitches is quoted per design.
Bucket hats
Where the logo goes
Front panel, centered, usually 2 to 2.75 inches wide. The brim limits how low the logo can sit, so tall logos get scaled to about 1.75 inches high. On a Decky 961 or 450 we can also run a small side hit above the brim seam as a second design.
What to expect on soft crowns
A bucket has no buckram. We hoop it with a cutaway backing so the panel does not pucker, and we keep fills light. Dense, photo-style fills on a bucket are the one thing we will push back on at the proof stage.
Dad hats
The classic dad-hat look is a small logo, 2 to 2.5 inches wide, on the front of an unstructured low-profile crown like the YP 6245CM or Decky 205. We keep text at 0.25 inches tall or more. Back-arch text above the strap is a popular second design, quoted per design.
5-panel caps
The flat front of a YP 6502 or Richardson 112FP is the easiest panel to embroider: no center seam, more room, and the structured versions hold a 3D puff logo (quoted per job). Logos up to 3 inches wide fit.
Artwork
- Vector preferred: AI, EPS, PDF, SVG. A 300 dpi PNG works for most embroidery.
- Tell us the hat color and your thread colors, or let us match on the proof.
- Digitizing is $18.99 one time per design, standard 2-day. We keep the file for reorders.
Questions
Can you embroider an unstructured bucket hat without puckering?
Yes. We hoop it on a cap frame with a cutaway backing and keep fill density moderate. The proof will flag any artwork that is too dense for a soft crown.
Is there a minimum for embroidered hats?
No hard minimum. Pricing starts at the 12-23 tier, $8.00 per hat for decoration, and breaks every 24 pieces.
Do you charge digitizing on reorders?
No. The $18.99 digitizing fee is one time per design. Reorders go straight to proof.