Custom caps and hats
A custom cap starts with the hat itself, because panel count, crown shape and brim are fixed at the tooling stage and the decoration is then chosen to suit what has been built.
We design and manufacture custom caps, hats and beanies for attractions, retailers, brands and promotional distributors across Australia. Headwear is where most of the group's development work sits, and a job can begin with an existing style decorated with your artwork or with a hat built to your own panel count, crown shape and brim.
Development and sampling run at the group's plant in Dongguan, and decoration can be finished on our print floor in Sydney when a job has to land close to its delivery date. Stock for the Australian market is warehoused in Sydney, so a range that sells can be reordered from there.
Embroidery in 2D or 3D reads as premium and survives a full day outdoors, although a complex character will lose detail at cap scale. For gradients and photographic artwork a DTF transfer or a sublimated panel does the job, and the placement is worked out around the seams so that the design registers cleanly.
What we supply
Structured caps
The standard line for brands, staff uniform and promotions, with embroidery or a transfer on the front panel and your artwork adapted to the shape.
Trucker caps
A mesh-backed style with a large front panel that suits character artwork and bold logos, and sells well to teens and adults.
Bucket hats
Sublimated, embroidered and animal bucket hats for families and retail ranges, with artwork that can run edge to edge across the hat.
Beanies
Knitted beanies for winter ranges and night events, decorated to sit alongside the caps and apparel in the rest of the range.
Plush and novelty headwear
Plush hats, animal shapes and novelty designs such as our jumbo koala hat, developed for attraction shops and zoo retail.
Wide-brim and legionnaire styles
Sun-safe styles for school groups, outdoor staff and any venue or organisation that works under a sun policy.
How a job runs
Brief
Send us the style you have in mind, your artwork, a rough quantity and the date you need the hats, and we will suggest the construction and decoration.
Free mock-up and quote
Every quote comes with a free mock-up showing the artwork on the hat, so placement and colours can be agreed before money is committed.
Sample and approval
The factory runs a sample so you can check the fit, the crown and the decoration, and a licensed job goes through the licensor's approval here.
Production and delivery
Quality control staff work on the production floor, and finished hats are delivered to you or held in our Sydney warehouse for reorder.
Typical product
A starting point, not a catalogue. Almost all of it can be made to your artwork.
Questions from buyers
Can you make a fully custom cap from scratch?
We can build a cap to your own panel count, crown shape and brim at the group's plant, and sample it before production starts.
Which decoration works best on caps and hats?
Embroidery suits logos and simple artwork, while DTF transfer or a sublimated panel suits gradients and photographic detail, and we recommend one when we see the artwork.
What is the minimum order for custom caps?
The minimum depends on the style, the construction and the decoration, so we confirm it with each quote, and short runs are a scheduling decision because the line is ours to book.
How long do custom caps take to make?
Timing depends on whether the hat is an existing style or built from scratch, and licensed work adds an approval stage, so tell us your date and we will confirm it when we quote.
Do you supply promotional distributors and resellers?
We supply the trade directly, and what we make for a distributor goes out under that distributor's name, with free mock-ups and free production photography.
Articles for custom caps and hats
Decoration methods for attraction merchandise
DTF, sublimation and embroidery each suit different fabrics, artwork and order sizes. How the method gets matched to the product.
Read
Souvenir headwear: styles, decoration and range
Headwear is the highest-turning souvenir category in most Australian attractions. The styles that move, the decoration that survives, and how a range is built.
Read
Staff uniforms at visitor attractions
Uniform sits in a different budget and a different supply chain to the merchandise beside it. The wear specification, colour matching and mid-season replacement.
ReadTell us what you need made
A quantity, a date and who it is for is enough to start.