How to Design a Custom Hat People Will Actually Want to Wear

 

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By PAGE Editor

Custom hats are a fantastic way to increase brand visibility or promote your team, organization, or event. However, most of the time, they end up stuffed at the back of a drawer or left behind at the event venue. This could be due to improper fit, or they’re itchy, uncomfortable, or just plain ugly. If you want your custom hat to help you get the exposure you want, you need to think beyond just putting a logo on it. There’s an art to designing wearable, stylish hats, and we’ll explain it now, step-by-step. 

Pick the Right Hat Style 

Not every hat style is suitable for your brand; you have to consider your audience, the climate of where they live, their sense of style, age, hobbies, and lifestyle. 

  • Trucker hats: A fantastic all-rounder, built to last.

  • Dad hats: Soft and unstructured for a relaxed look. 

  • Straw hats: Ideal for vacationing audiences or coastal brands.

  • Bucket hats: This retro style is making a comeback.

  • Snapbacks: A staple of modern urban and youth fashion. 

  • Beanies: Great for winter clothing, streetwear, or skating brands. 

  • Visors: Popular with older generations.

A good custom hat company like Monterey Hats should offer a variety of styles. Look at what your target audience already wears and use that to guide you. 

Prioritize Comfort and Fit 

Even the best-looking hat won’t make it out of the closet if it’s uncomfortable. Materials and fit are key. Opt for adjustable closures, like snapback, Velcro, or a metal buckle to make sizing easy. Breathable materials like cotton or mesh help prevent overheating, even in hot climates. Consider lightweight and flexible fabrics. Ideally, you should try a sample before you make a bulk order so you can give your hat a test run. 

Put Thought Into the Logo 

You want your logo to be visible; that’s the whole point. However, be careful not to make it overwhelming. An oversized logo can make a hat look cheap and immediately identify it as a swag item. You want to get the scale right, but also the material or print method. Here are some popular options: 

  • Rubber PVC patches: These patches are waterproof with a soft, tactile feel.

  • Woven patches: Best for super-fine levels of detail and a smooth surface. 

  • Embroidered: Can be directly stitched onto a cap or attached as a patch for simple designs. 

For interchangeable patches, like those used in the military, hook-and-loop backing is a must. Other backing options include iron-on, heat press, and adhesive. For patches, edging is another consideration: common styles include merrowed edge, heat cut birder, or laser cut for a super-seek finish. 

Other Tips

Color is important if you want people to wear your hat. Black may match everything, but it’s not ideal for hot, sunny climates. Two-tone designs with a pop of color on the prim or mesh panel keep things interesting, but don’t overdo it. If using multiple colors, make sure they complement your brand palette. 

Endnote

Designing a wearable hat involves research, planning, and mindful decision-making at every stage. Ultimately, it pays off to get it right: when people love and wear your hats, it’s a long-term marketing win for you.


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