Custom fitted and snapback hat questions, answered
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.
What if my logo is more than 6,000 stitches?
Every embroidery price covers up to 6,000 stitches. Above that, each additional 1,000 stitches adds $1.50 per piece at 12-23 pieces, $1.00 at 24-71, $0.60 at 72-95 and $0.50 at 96 or more, rounded up to the next 1,000. So a 12,000-stitch logo adds $6.00 per piece at 24 and $3.00 at 144. We digitize first and tell you the exact count with the proof before you approve anything.
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.
Do I get a proof?
Yes. A digital proof before production with one round of revisions, included.
Can I mix cap colors or sizes in one order?
Yes. Same logo, any mix of colors and sizes, priced as one order.
Can I send my own caps?
Yes. $2.00 per cap handling plus decoration. Industry spoilage allowance is about 4%; we aim for zero but cannot replace customer-supplied caps damaged in production.
Where are the caps decorated?
In Battle Born Clothing's shop at 3 Pebble Beach Dr, Yerington, NV 89447. Embroidery and leather patches are done in-house.
Do you ship nationwide?
Yes. Freight is quoted with the order.
What if there is a mistake?
If the error is ours, we redo it free.
Which cap should I pick for a group I cannot measure?
A snapback such as the Richardson 112, YP 6089M or Flexfit 110F, or the one-size New Era NE400.
Which blanks do you stock?
Flexfit, Richardson and YP Classics through SanMar (Reno warehouse first) and S&S Activewear; Zapped Headwear as a dealer; Decky direct; New Era through SanMar.
Can you embroider the side or back too?
Yes. Side hits and back arch text are quoted per job as a second placement.
Do you make woven patches or custom-built caps?
No. We decorate stock blanks with embroidery, leather patches and pressed DTF transfers. No woven patches, no custom-manufactured caps.
How do reorders work?
Your digitized file or patch file is on file. Send the quantity and colors; the same 28-day turnaround applies from proof approval.
Can an AI agent request a quote for me?
Yes. Battle Born Clothing publishes an RFQ guide for AI agents at https://battlebornclothing.com/pages/ai-agent-rfq-guide.
Get a quote
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.