Custom Embroidered Hats with Your Logo
A stitched logo on a cap costs $12.00 a unit plus a one-time $75.00 setup fee per design, added on top of the blank hat price, and every style's order ladder starts at 24 pieces. That is a much lower floor than the 300-piece minimum on promotional totes, so a single team or one event can clear it. The decorated order as a whole does need to reach $2,500, and exceptions are possible. Once volume breaks are folded in, trucker caps and snapbacks land between $32 and $45 a piece, cheaper as the quantity climbs through 48, 100, 144 and 250, whether the blank underneath is an OTTO CAP mesh-back trucker or a New Era flat bill snapback. Encore embroiders every one of them in its own San Diego shop instead of shipping blanks out to a print vendor. Same rate, same crew, 24 pieces or 250.
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FAQ
How much do custom embroidered hats cost?
Embroidery runs $12.00 per unit with a one-time $75.00 setup fee per design, added to the blank cap price, which itself ranges $23.60 to $48.00 depending on style and brand. Bulk pricing is available based on quantity ordered and the discount varies by product. Do you have a specific budget you're looking to stay inside? Give us a call or send an inquiry and we'll see what we can do for you.
What's the minimum order for custom embroidered hats?
Twenty-four pieces per style. That's the floor on the order ladder itself. Separately, Encore holds a $2,500 minimum on the decorated portion of an order as a whole, and that's a dollar figure, not a piece count, so it can be one style at a solid quantity or several styles stacked together to get there. Exceptions to either number are possible; it's worth asking rather than assuming a small run gets turned away.
Do you make custom trucker hats?
Yes, in both mesh back and twill back builds. The OTTO CAP 5 Panel High Crown Mesh Back Trucker blanks at $23.60 and comes to $38.73 embroidered at 24 pieces, down to $32.36 at 250. The Richardson 112FP Five-Panel Trucker runs a bit higher, $45.03 at 24 and $37.72 at 250, since its blank costs more to start. Both take the same $12.00 embroidery and $75.00 setup as every other style in the catalog.
Can I buy hats in bulk for a company?
That's most of what this catalog is built for. OTTO CAP, which Encore stocks directly, is a real wholesale headwear brand rather than a print-on-demand shortcut, and pricing steps down at 48, 100, 144 and 250 pieces on every style. The $2,500 decorated minimum applies to the order as a whole, so a mixed order of a few styles for a company store counts the same as one style bought deep. Sixty-one active SKUs. That's a working range built for pricing and specs, not a giant selection to browse.
What hat brands does Encore carry?
OTTO CAP, New Era, Richardson, Under Armour, Nautica, Titleist and Srixon, spread across 61 active styles. New Era has its own 12-style collection, OTTO its own 16, and Richardson a smaller 4-style lineup. The rest sit across trucker, snapback, flat bill and bucket styles that don't belong to a single-brand collection.
What affects the final price of an embroidered logo?
The $12.00 per-unit rate and the $75.00 setup are the baseline, but three things move the number from there: placement, since a left-panel logo digitizes differently than a full front, stitch count, because a dense design takes the machine longer to run, and thread colors, since more colors mean more stops and more thread changes per cap. Simple beats detailed on price every time. A one-color wordmark on a flat panel is the fastest and cheapest thing to embroider; a multi-color crest costs the most. Screen printing and patches aren't priced on these SKUs, only embroidery is.
What's the difference between a structured and unstructured cap?
Structured caps hold a stiff front panel and a defined crown shape, which is what most flat bill and snapback styles use. Unstructured and stretch-fit caps drop that lining, so the crown sits flatter and fits closer to the head, which some buyers prefer for an embroidered logo since the surface sits smoother. The catalog carries both, plus adjustable caps, bucket hats and visors for programs that want something besides a ballcap silhouette.