Custom Hats

Custom Hats

Custom Hats - Difficulty in the USA

Once a hat is constructed we have many embroidery limitations. The maximum height for embroidery in the USA is only 2.5 inches tall in the center front of a hat and only 2 inches for a beanie. Nothing is easy considering the limited embroidery area, the front two hat panels are curved and embroidering on mesh is reserved for only the most experienced.  

Custom Hats - Design Optimization

Optimizing a logo for embroidery is the first step to creating high-end, quality custom hats. Embroidery machines have limitations, so setting up the design must work within these requirements while still achieving finished artwork that a company can be proud of. We take the time, energy and effort for free to do a full art review of the design. We measure all of the design elements to make sure the thickness of each stitch of thread element complies with our strict quality standards to be assured that every logo is optimized for embroidery. 

Custom Hats - Digitizing, The Science of Art

Having professional artists that are also master digitizers allows the design to be digitized considering the stitch pattern flow to compliment the embroidery design. Many times our artists will use several different stitch patterns and underlay within one design depending on the design complexity. However, before a custom hat design is ever digitized, there are so many considerations prior to starting the process. A few of the most important to consider are the hat material(s), structure, construction and buckram backing. These aspects determine the best type of stitch to use for the job. 

Custom Hats - Mockups & Approvals

Even with all of these considerations and protocols we send every customer a digital art approval, color coordination mock up prior to embroidery production. This ensures the customer reviews and approves the design on every hat color before we proceed with production. Allowing customers to make last minute thread color changes so the customer is 100% satisfied. The final step before full production is to have an onsite production manager visually approve the first embroidery production run. 

Custom Hats - Overseas Programs

Producing custom hats overseas has many benefits allowing customers to customize every aspect of the hat. Because the custom hat is being made from scratch, decorations can be made to the hat that can not be done domestically.  Every aspect is better with a custom hat overseas project except waiting 120 days for production to land. 

Custom Hats - Domestic Post Production 

Most custom hats are embroidered after the hat has been constructed and in stock in one of our US warehouses. Allowing a quick production turnaround time of about 2 weeks requested by most customers.  Even though making domestic custom hats in the USA has limitations we are still able to embroider in most locations on a hat.