Before starting a hat embroidery business, you need to realize one thing - customers wouldn't always come to you with hats on their own. Most of the time, customers will only make a request and buy the embroidered finished hat, and you will have to shop hat blanks on your own.

Just as cooking is a hundred times more difficult than eating, shopping for hat blanks can be a lot more complicated than wearing a hat. Making a choice means you need to take into account a variety of factors. Choosing cost-effective blanks and having a stable source of purchase will greatly help your embroidery business. This blog will give you a comprehensive overview of how to buy whiteboards. This blog will introduce the following sections to help you pick the suitable hat blank:

# Size of hat blanks

# Construction of hat blanks

# Materials of hat blanks

# Types of Hat Blanks

# Brands of Hat Blanks

# Purchase channels of hat blanks

# Size of hat blanks

The hat size standard is based on the head circumference. To measure the head circumference size you can use a soft ruler around the head (over the forehead and the back of the head the most prominent part) for a week, and keep the soft ruler can be slightly rotated state. At this time the circumference of the head that is the head circumference size, so as to determine the appropriate hat size standard.

But often your customers aren't adults. Many orders come from schools and school groups (such as basketball clubs, cheerleaders, etc.).Students have smaller head circumferences than adults and each age group's head circumference varies more, so you can refer to the table below for their hat sizes:

Common hat size and related sizes are listed in the table below:

Size	Centimeters	Inches	US Hat Size	Fit
S	53	20 1/2	6 5/8	One Size Fits Most
	54	21 1/4	6 3/4
	55	21 5/8	6 7/8
M	56	22	7
	57	22 1/2	7 1/8
	58	22 7/8	7 1/4
L	59	23 1/4	7 3/8
	60	23 5/8	7 1/2
XL	61	24	7 5/8
	62	24 1/2	7 3/4
XXL	63	24 7/8	7 7/8
	64	25 1/4	8
	65	25 5/8	8 1/8

But often your customers aren't adults. Many orders come from schools and school groups (such as basketball clubs, cheerleaders, etc.).Students have smaller head circumferences than adults and each age group's head circumference varies more, so you can refer to the table below for their hat sizes:

Size	Centimet ers	Inches	US HatSize	FIT
	47	18 1/2		Infants
XSM	48	19	6
S	49.2	19 3/8	6 1/8		Toddler
	50.2	19 3/4	6 1/4
M	51	20 1/8	6 3/8			Child
	52	20 1/2	6 1/2
L	53	20 7/8	6 5/8				Youth
	54	21 1/4	6 3/4
XL	55	21 5/8	6 7/8
	55.9	22	7

Tips: These charts are for reference only. Specific hat sizes may vary depending on material, construction and manufacturer.

# Construction of hat blanks

Hat embroidery is done mainly on the crown, which is a necessary part of a hat's structure. This space is large and relatively flat, making it more suitable for embroidery. However, due to fashion and practicality, hats usually have other structures, such as brims, eyelets, top buttons, hatbands, and so on.

Below I will give you an overview of what makes up a hat.

Crown: the center part of the hat, covering the area of the head. It has different shapes, such as flat top, round top, pointed top, etc. Its shape and design determine the overall appearance and style of the hat. The structure of crown can also affect the comfort and fit of the hat.

The Crown has three different heights - high, medium, or low, and medium is the most common. The hat's profile is made up of panels. The more common ones are the 5 Panle, 6 Panle, and 7 Panle. The 5-Panel hat is best for embroidery because they have a seamless front panel that provides uninterrupted space for the embroidery design. However, the customers prefer the 6 Panel because the center line on the front panel of the hat will give the hat a more stylish look. Baseball caps are a typical 6-panel hat.

Brim: The front part of a hat, usually a protruding flat or curved section. It shades the sun and protects the eyes from the irritation of direct sunlight. The length and angle of the brim can also affect the function and appearance of a hat. It is also called Bill, Visor.

Newbies often ask, "Can I embroider on the brim of my hat?" Unfortunately to tell you, No! Any hat you see has embroidery on the brim, which is done before the hat is assembled. Brims are usually made of harder materials and may be damaged if you try to embroider on the brim by machine.

Lining: Located inside the hat and provides comfort and protection. The lining is usually made of fabric material, which prevents the head from direct contact with the hat and increases its wearability.

Sweatband: A band located inside the hat that fits snugly around the head to absorb sweat and increase comfort and stability.

Hatband: A decorative band around the bottom of the hat, often used to provide additional aesthetic appeal. Hatbands usually are made of fabric, leather, ribbon, and other materials.

Ventilation Holes: These may be small holes or well-designed ventilation structures. Improves breathability, reduces the internal temperature of the hat, and increases wearing comfort. The mesh back of trucker hats is designed for this purpose.

Top button: A small button located in the center of the crown that holds the fabric or material together. It prevents the hat from deforming or collapsing and ensures that the hat maintains a stable shape.

Adjustable Features: The back of the hat usually has adjustable parts such as a buckle, drawstring, and so on, to adapt the hat to different head circumferences and increase the flexibility of wearing. Most common on baseball caps.

Ornaments and Decorations: It can be feathers, laces, patterns, badges, and so on, depending on the design and style. It adds a personalized, fashionable element that makes the hat more unique. Embroidery is exactly the most typical kind of decoration. It is important to note that we are shopping for hat blanks - hats without prints, embroidery, or other craftsmanship, so remember to stay away from any hat with decorations!

# Materials of hat blanks

Hats are made of a wide variety of materials, and those suitable for embroidery are usually made with a certain stability and density of weave to ensure the clarity and durability of the embroidery stitches. Here are some common hat materials suitable for embroidery:

Cotton: Cotton hats are a great material for embroidery. Cotton is soft and easy to work with, and can showcase the details and results of embroidery very well. At the same time, cotton hats are also breathable and comfortable, suitable for spring and summer seasons, and relatively easy to carry and clean.

Hemp: Hemp hats are also one of the suitable materials for embroidery. Hemp is light and breathable, which facilitates the embroidery operation, especially suitable for making summer or casual-style embroidery hats.

Canvas: Canvas is a stable and durable material that is commonly used for hats. It has a certain thickness and density of weave which makes it suitable for embroidery.

Wool: Thin fluffy woolen hats are also suitable for some embroidery. Especially warm hats such as wool caps and cashmere hats can have some fine embroidery designs done on the surface of the hat.

In contrast, materials that are harder or less susceptible to puncture are not suitable for embroidery.For example, the following kinds:

Leather: Leather hats are mostly with better texture and durability, suitable for fall and winter season wear. However, leather hats are usually harder and difficult to penetrate, so they are not suitable for embroidery. Artificial leather hats are similar to real leather hats.

Synthetic Fiber: Synthetic fiber hats are usually lightweight, wrinkle-resistant and easy to clean. Synthetic fiber materials such as polyester, nylon, and so on tend to have a smooth surface and high elasticity, not good for embroidery, and the embroidery thread is difficult to go through.

Straw: Straw hats are usually made of woven straw rope, the material is soft and easy to deform, less suitable for embroidery.

Puffy Fluffy: For too fluffy hats, the embroidery effect may be unclear, and the stitches are easy to cover up.

In conclusion, when choosing a hat blank to embroider, you should consider the quality and stability. This is because some materials with thin and unstable textures may affect the embroidery. The best choice is the hat material with a certain thickness (but not too thick) and stability to ensure that the embroidery is long-lasting and beautiful.

# Types of Hat Blanks

In general, hats can be categorized into structural and unstructured hats based on their shape and whether or not the hat has an internal support structure.

1. Structural hats:

Structural hats have a distinct external shape and internal support structure. They tend to be made of hard materials ( such as plastic, metal, leather, etc.) or structural materials (such as plastic-reinforced fibers). Structured hats can maintain a stable shape and are less likely to deform.

Some common structured hats suitable for embroidery include:

Trucker Hat: This is a structured hat with a domed shape and a wide brim, usually made of mesh fabric for ventilation. Trucker hats can be used for embroidered designs or monograms and are often used for personal or group logos, branding, or slogans.

Baseball Cap: The baseball cap is a common structured cap with a domed top and brim. It can be used for embroidery and is widely used in sports, branding, and other applications.

Golf Cap: The golf cap is a common structured hat with a flat top and long brim. Its brim usually is wider and curved at the front and back to effectively shade people from the sun. It is often used to embroider golf course and golf tournament logos or branding. It is usually more formal and professional, suited for golf enthusiasts or promotional events.

Snapback Cap: The Snapback Cap is a structured cap with a flat top and adjustable back band. It is suitable for embroidering fashion logos, patterns or personalized designs, and is commonly used for fashion trends and street culture.

Hard structures on hats will make embroidery more difficult and require a higher level of embroidery. Embroidery tries to avoid penetrating hard materials to avoid affecting the structure of the hat. It is necessary to choose the right location for embroidery, which is usually more common on the front or side of the hat.

2. Unstructured Hats:

Unstructured hats are hats that have no internal support structure or only slight support. They are usually made of soft materials (such as fabric, wool, fleece, etc.) and have no fixed shape. Unstructured hats are more flexible as well as moldable, allowing them to better fit the shape and size of your head.

Some common structured hats suitable for embroidery include:

Beanie Hat: Beanie Hat is a loose-fitting hat without a brim. It is usually made of a soft material, such as wool or cotton fabric, and is suitable for personalized designs or brand logos.

Bucket Hat: Bucket hat is a domed hat with a wide brim. It is usually made of soft materials such as cotton or linen. The entire surface can be embroidered, making it suitable for personalization, trendy branding, or promotional campaigns.

Beret: Beret is a flat-topped, wide-brimmed fedora, usually made of wool or tweed. It is often used in embroidered art designs and appears as a fashion accessory.

Peaked Cap: The peaked cap is often categorized as an unstructured hat. It has a narrow, flat brim, no fixed structure or support, and is often made of soft materials such as cotton or linen. It is often used for outdoor sports or casual styles and can be embroidered with patterns, letters, or logos.

Unstructured hats are relatively soft and will be easier to embroider. Beginners are advised to start practicing with soft hats if they want to try hat embroidery. The embroidery area is large, which usually allows you to embroider on the all face of the hat. You need to use an appropriate backing, such as a Hot Melt backing, to keep the embroidery stable.

It is also important to note that some hats may be in between structured and unstructured hats, depending on their design and manufacturing methods. The division into structured and unstructured hats is primarily intended to characterize the shape and support characteristics of hats to help people better understand the different types of hats.

# Brands of Hat Blanks

With thousands of hat blank brands on the market for you to choose from, it is easy to be dazzled and confused. Considering the quality, it is recommended you choose a well-known and reputable brand in the hat manufacturing industry.

Yupoong/Flexfit: Yupoong is a long-established hat manufacturer founded in 1974. Their hats are known for their excellent quality and diverse styles. Yupoong offers a wide variety of hats, including baseball caps, peaked caps, sports caps, and more. Their hats are made from high-quality materials that are suitable for embroidery. Yupoong's hats usually have a classic style and comfortable fit, making them perfect for personalized embroidery customization.

New Era: New Era is a reputable hat brand that was founded in 1920. They are known for making high-quality baseball caps and are the official approved hat supplier to Major League Baseball. New Era hats are made from premium materials for superior quality and comfort. They offer a wide selection of caps in a variety of styles and colors that are suitable for embroidery customization.

Richardson: Richardson is a brand that specializes in sports hats and was founded in 1970. Their hats are of excellent quality and are known for their wide selection of styles and colors. Richardson's hats are made from high-quality materials that offer superior breathability and comfort and are perfect for embroidery. Their hats are suitable for various sports and outdoor activities.

Otto Cap: Otto Cap is a brand that offers a diverse selection of hats. Their caps come in a wide variety of styles and colors for different occasions and needs. Otto Cap's caps are reliable in quality and suitable for embroidery and customization. They offer a variety of styles of caps and can meet the demand for personalized embroidery.

In addition, you can choose the appropriate brand according to your needs and preferences.

# Purchase channels of hat blanks

The most common channels to buy hat blanks are online shopping and professional hat suppliers. If you search online, you can browse various brands and styles of hats by searching for keywords such as "blank hat" and choose the right one to buy; if you shop offline, you can go to the market directly to look for and choose, which is more conducive to feeling the quality, color, and style of the hats.

Now recommend you some common hat blank shopping site:

Amazon (https://www.amazon.com)

PROS: As one of the world's largest online retailers, Amazon offers a wide selection of hat blanks at competitive prices, sometimes with fast delivery and multiple payment options.

Cons: There is a risk of counterfeit goods, sometimes additional duties and shipping costs are required, and the shopping experience may vary from seller to seller.

Backcountry (https://www.backcountry.com)

PROS: Backcountry offers customers a wide range of outdoor gear and supplies, including hat blanks, a great selection of brands and expert advice.

Cons: Higher prices, sometimes extra duty and shipping costs, relatively strict return policy.

Blankstyle (www.blankstyle.com)

PROS: Specializes in offering a wide selection of blank clothing and hat blanks, including baseball caps, peaked caps, and more, with a large selection of colors and styles for personalization. Prices are relatively affordable.

Cons: Selection of particular styles and colors may be limited, and some special and customized styles may be lacking.

Cap Wholesalers (www.capwholesalers.com)

PROS: Offers a variety of types and styles of hat blanks to pick from, lower prices, and an extensive inventory.

Cons: Product quality and reliability may vary, website interface may not be modern enough.

eBay (https://www.ebay.com)

Pros: eBay is a global auction and shopping site that offers a wide variety of hat blanks, both used and new, and sometimes unique treasures and discounts can be found.

Cons: The quality of the merchandise varies, and there is a risk of fraud and impersonation of name brands, requiring manual selection and identification.

Lids (https://www.lids.com)

PROS: Lids is a retailer specializing in hats and related accessories, offering several brands and styles of hat blanks, and sometimes you can find embroidery-ready options.

Cons: The prices are relatively high.

Mega Cap (www.megacapinc.com)

PROS: Offers a wide selection of hat blanks, relatively low prices, and extensive inventory.

Cons: Website interface may not be user-friendly enough, need to pay close attention to product descriptions and details.

Moosejaw (https://www.moosejaw.com)

PROS: Moosejaw is an outdoor-focused retailer that offers hat blanks from several high-quality brands, sometimes with discounts and promotions.

Cons: Prices are relatively high, and product inventory is limited and may be out of stock.

Otto Cap (www.ottocap.com)

PROS: Offers a diverse selection of hat blanks, is more reasonably priced, and offers international delivery.

Cons: Some styles and colors may be limited, and the return and refund policy may be stricter.

Outdoor Cap (https://www.outdoorcap.com)

PROS: Outdoor Cap is a maker of hats and offers a wide range of hat blanks that are of better quality, as well as a wide selection of colors and styles.

Cons: Prices are relatively high and minimum order quantities may be required.

Pacific Headwear (https://www.pacificheadwear.com)

PROS: Pacific Headwear is a manufacturer specializing in hat blanks with reliable product quality for embroidery and custom designs.

Cons: It is not available for direct purchase and needs to be purchased through one of its authorized retailers or distributors.

REI (https://www.rei.com)

PROS: REI is a famous outdoor store chain in the U.S., offering several brands of hat blanks with reliable quality, official distributors and after-sales service.

Cons: Relatively high prices, selection may be limited by stock availability, international shipping costs extra.

S&S Activewear (https://www.ssactivewear.com)

PROS: S&S Activewear is an apparel wholesaler specializing in printing and embroidery, offering a variety of hat blank options suitable for embroidery and reliable quality.

Cons: You need to register as a wholesaler to make purchases, for business users.

ShirtSpace (https://www.shirtspace.com)

PROS: ShirtSpace offers all types of hat blanks, offers a wide selection of brands and styles, is more plentiful, and is reasonably priced.

Cons: The site's interface is relatively simple and may not display information comprehensively enough.

TSC Apparel (https://www.tscapparel.com)

PROS: TSC Apparel is a wholesaler that offers a wide variety of clothing and accessories, a wide selection of hat blanks, and relatively low prices.

Cons: Purchase quantities can be demanding.

Wholesale Hats (www.wholesalehats.com)

PROS: Offers a large selection of hat blanks, good for bulk purchases, relatively well stocked.

Cons: Prices can be high, selection of certain sizes and styles may be limited.

Richword（https://richword.com）

PROS: Bring you the price and quality of China's best suppliers to meet your commercialization needs.

Cons: The logistics and commodity system is not good.

If you need to buy a large quantity of blank, you can consider buying them through wholesale or group buying, which usually offers you a discount. It is also important to pay attention to the specials of the relevant merchants regularly, as there may be markdowns, discounts, or promotions that you can also get a discount. It is also essential to familiarize yourself with the buying and protection policies of different websites.

This is all about this blog, hope it can provide you with a good reference when choosing a hat blank! If you have any good tips or suggestions, please feel free to share them in our Facebook group. Thanks!