Hat IQ

Use this guide to learn more about hats, patches, and what to look for.

Richardson logo
Yupoong logo
Outdoor Cap logo
Flexfit logo
Decky logo
Cobra Cap logo

Hat Brands

We carry a variety of quality hat brands to choose from. Each brand is unique and has varying levels of fit, craftsmanship, and style. Click on a brand below to learn more: Richardson, Yupoong, Outdoor Cap, Flexfit, Decky, Cobra. 

Examples of a structured and an unstructured hat.

Structured | Unstructured

A structured hat has a stiff front crown that holds it’s shape. An unstructured cap is not stiff and has a more relaxed, informal look. Unstructured hats are also referred to as “dad” hats. 

Examples of a five panel and a six panel hat.

Five panel | Six panel

A six-panel hat has a seam running down the center of the front panel. A five-panel hat has a single panel in front without a seam.  

Examples of a flat bill and curved bill hat.

Flat bill | Curved bill

Traditionally, baseball-style caps have a pronounced curve on the front bill. Modern fashion has trended to a flat-bill design. Most modern hat styles offer a curved and flat bill version of their base hats. 

Adjustable Snapback
Snapback
Hat with buckle enclosure
Buckle
Fitted hat
Fitted
Adjustable Velcro back
Velcro

Fitted | Snapback | Buckle | Velcro

These terms refer to the features on the back of the hat. 

  • Snapback: Adjustable plastic tabs that make a snapping noise when pressed together. This is the most common size adjustment method. 
  • Buckle: A metal buckle that adjusts the size of the band. 
  • Velcro: Velcro tabs that adjust the size of the band. 
  • Fitted: This style is not adjustable and comes in sizes. There is no opening on the rear band.

Trucker Hat

A trucker hat is a style of hat that has a fabric (or foam) front panel and a lightweight, porous mesh on the back panel. Truckers are very popular for their light weight and cooling characteristics.

Flexfit™

Flexfit is a type of hat with polyurethane spandex woven into its sweatband for a comfortable stretch and fit. The spandex is also incorporated throughout the crown of the cap for added elasticity. 

Hat Patches

Woven patches

A woven patch is flat and made with thin polyester threads woven together to make a design. Woven patches are very durable and can capture more intricate detail than an embroidered patches. Our patches have the following specs:

  • 80 denier weight polyester thread
  • Up to 8 colors (black and white are considered colors)
  •  Merrowed or die cut border will not fray
  • Custom shapes and sizes

Patch Size and Shape

For most designs, we recommend patches that are 3.5 inches wide or less. Wider patches are available for certain designs. Custom shapes are also available. Our designer will help you select a patch shape that will fit your logo best. 

Patch Borders

Woven patches are usually finished with a merrowed border. A merrowed border is a border stitch that is .125 inches wide. This border stitch gives the patch a finished look and provides a thicker, embroidery-like edge. We also offer the option of die-cut edges without merrowing. This border type is useful for more intricate shaped patches. 

Patch Colors

Our patches can include up to 8 colors. (Black and white are counted as colors) Our designer will match the Pantone colors of your design as closely as possible. 

Leather Patches

These patches are laser-cut out of thin leather. The design is etched into the surface by the laser. Leather patches have the following options:

  • Various colors of leather
  • Border stitching

Woven patches vs. Embroidered patches

Woven patches are flatter and capable of finer detail than embroidered patches. We recommend woven patches for detailed logos and typography. Embroidered patches use thicker, heavier thread and have a three dimensional appearance because of their high-density stitching. We recommend embroidered patches for simpler, more retro designs.