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6 Most Popular Custom Hat Styles

Dan Arakawa - 02/18/2012

We receive several emails and calls per day from customers asking what styles of hats are most popular and stylish in today's market. Many times the specific type of customer will reflect what style cap or hat would be most popular to them. For example, a US military unit serving in the desert will find one style cap attractive while a company buying caps for a company barbecue party will like a completely different style hat. That being said, there are several hat styles that are popular no matter what type of customer you are. Here is a list of the 6 most popular style custom hats in today's market:

1 - Low profile, unstructured caps with velcro closure and light-weight cotton twill. This is a very popular style cap for promotional use because of its low cost and overall likability by the majority of people.

2 - Flex fit style caps. They combine the versatility of adjustable caps with the stylish look of fitted caps. The majority of the Flexfit brand caps come in two different sizes - S/M and L/XL. They look just like fitted caps but stretch to accommodate a wide range of head sizes using a special blend of fabrics. There is no hole in the back of the caps allowing large back embroidered if needed. Flex Fit hats are one of the more expensive style caps available.

3 - Medium profile, structured caps with either velcro or buckle closure. The military tends to find this style cap attractive because of its comfortable fit and head coverage. This style cap seems to be gaining in popularity among other customers too as the low profile hats become less popular.

4 - Heavy brushed cotton cap with contrasting sandwich visor. Great for customers looking for something just a little different. Looks especially great when the custom embroidery is matched to the sandwich color. For example a black cap with light gray embroidery and a light gray sandwich. These tend to be a little more expensive but feel very high quality.

5 - Washed and distressed hats. This style cap became popular in just the last couple years. We wash the fabric and distress the bill so it is frayed slightly to give the entire cap a stylish "worn" look. Combine with a frayed patch embroidered on the front of the cap to complete the look.

6 - Trucker style caps. Several years ago, foam trucker caps were one of the most popular style hats. Since then, their popularity has decreased significantly but recently there has been a bit of a revival. The style has changed to a lower profile style, with fabric front and with the mesh backing matching the front fabric color. For example, black fabric front with black mesh backing.

We hope that this list of popular cap styles is helpful in deciding which style to use on your next project. Please remember that there are hundreds of other styles of hats available and there is sure to be one that meets your specific needs.