Fitted hat sizing chart and how to size a group order
Measure around the head just above the ears and eyebrows, where a cap sits. Use the chart to match a hat size and a Flexfit range. Battle Born Clothing size-sorts every fitted order before packing.
Hat size to head circumference
| Hat size | Inches | cm | Flexfit range |
|---|---|---|---|
| 6 3/4 | 21 1/8 | 53.7 | XS/S |
| 6 7/8 | 21 1/2 | 54.6 | S/M |
| 7 | 21 7/8 | 55.6 | S/M |
| 7 1/8 | 22 1/4 | 56.5 | S/M or L/XL |
| 7 1/4 | 22 5/8 | 57.5 | L/XL |
| 7 3/8 | 23 | 58.4 | L/XL |
| 7 1/2 | 23 1/2 | 59.7 | L/XL |
| 7 5/8 | 23 7/8 | 60.6 | L/XL or XXL |
| 7 3/4 | 24 1/4 | 61.6 | XXL |
| 7 7/8 | 24 5/8 | 62.5 | XXL |
| 8 | 25 | 63.5 | XXL |
Flexfit ranges by style
| Style | Ranges |
|---|---|
| Flexfit 6277 | XS/S, S/M, L/XL, XXL |
| Flexfit 5001 | S/M, L/XL (XS/S and XL/XXL by color) |
| Flexfit 6210 | S/M, L/XL, XL/XXL |
| Flexfit 6297F | S/M, L/XL, XL/XXL |
| Flexfit 180 Delta | S/M, L/XL |
| Flexfit 6100NU | S/M, L/XL |
| Richardson 110 R-Flex | S/M, L/XL |
| New Era NE1000 39THIRTY | S/M, M/L, L/XL |
Splitting a group order without measuring
For a mixed adult group, start from about 15% S/M, 55% L/XL and 30% XXL where XXL exists; for a two-range style, about 35% S/M and 65% L/XL. Skew toward L/XL for men's crews and toward S/M for mixed or women's groups. Youth programs use the 6277Y.
Leftovers
Order two or three extra in the most common range. Leftover caps in an odd size are the main cost of true fitted orders; stretch-fit ranges nearly eliminate it.
Questions
What if someone is between ranges?
Size up. The band is more comfortable slightly loose than tight.
Do sizes cost different amounts?
No. Adult sizes are one blank price; youth styles are quoted separately.
Can you label caps by size for distribution?
Yes. Tell us how you want them sorted (by team, by name list) and we will pack to it.