Wholesale Blank 5 Panel Foam Mesh Trucker Hat - 7011

At Foremost Hat, we make it easy to create hats that truly represent your vision. Whether you need a single bespoke piece or a bulk order, our "No Minimum Order" policy means ultimate flexibility for your business or personal project.

Choose from a wide range of customization options to bring your logo to life:
Flat Embroidery: Crisp, classic, and timeless – perfect for clean lines and detailed designs.
3D Embroidery: Add depth and dimension with a bold, raised effect that makes your logo pop.
High-Quality Print: Vibrant colors and intricate details, ideal for complex graphics and photorealistic designs.
PVC Patch: Modern, durable, and weather-resistant with a tactile, rubberized finish.
Leather Patch: A sophisticated and rugged look, perfect for adding a touch of rustic luxury.
Embroidery Patch: Versatile and classic, offering texture and a handcrafted feel that can be sewn on.

Choosing the Right Customization Method

• Embroidery: This method adds texture and durability, making it ideal for logos with simple shapes or text. It works best on thicker fabrics, but avoid overly intricate designs, which may not translate well. Flat embroidery stitches designs directly onto the surface, while 3D puff embroidery uses a foam insert for a raised, three-dimensional effect.
• Printing: For detailed logos, designs with multiple colors, gradients, or photographic images, printing is often the better choice. It's also suitable for thinner fabrics.
• Patches: If you're looking for a unique, raised effect, patches are a versatile option that works on most hat types. However, they might not be ideal for very curved or small areas.

Custom Embroidery for Hats

Embroidery offers a classic, textured look, adding durability to your custom hats. It's an excellent choice for designs with simpler shapes or text.

Choosing the Right Embroidery Method

• Flat Embroidery: This technique involves stitches lying flat on the fabric surface, offering a clean and traditional appearance.
• 3D Puff Embroidery: For a more dynamic, raised effect, 3D puff embroidery uses a foam insert beneath the stitching, making your design stand out.

Optimal Embroidery Locations

• Caps:
  • Front: Your design should begin at least 1.8 cm from the visor. The maximum area is 11 cm wide x 5 cm high. (Note: Avoid using embroidery on ultra-thin fabrics like nylon.)
  • Side: Designs should start no less than 2 cm from the back strap. The maximum area is 7.5 cm wide x 3 cm high.
  • Back: Customization should begin at least 1 cm from the top of the back strap. The maximum area is 7.5 cm wide x 3 cm high.
• Bucket Hats (without lining or with a fixed lining):
  • Crown: Designs should start at least 1.8 cm from the edge. The maximum area is 11 cm wide x 5 cm high.
• Beanies (without lining or single-layer design):
  • Cuff: There are no size restrictions for customization on the cuff.

Tips for Best Embroidery Results

• Design for Simplicity: Due to the small hat areas, overly detailed logos won't translate well. Opt for bold, simple designs that are easily recognizable.
• Readable Fonts: If your design includes text, choose a font that's legible and clear. Avoid intricate or overly thin fonts, as they may not embroider well. The thickness of embroidered letters should be at least 0.4 cm to prevent blurring.
• High-Quality Artwork: Always submit vector files (like .AI or .EPS) for crisp, professional results. PDF format for vector files or PNG files with at least 150 DPI are also acceptable.
• Embroidery Specifics:
  • The height of your embroidery pattern shouldn't exceed 8 cm.
  • The embroidery placement on the front panel of a cap should be at least 1.8 cm above the visor.
  • Limit your embroidery to 5 colors to avoid undesirable contrast.
  • Stay within a maximum stitch count of 15,000 stitches for regular designs and 25,000 stitches for large text and clipart.
• General Guidelines:
  • Design true-to-size graphics.
  • Use solid shapes and colors only.
  • Use transparent backgrounds for your graphics.
  • If using our downloadable templates, remember to delete the guide layers before saving.
  • The best embroidery designs are typically text-based or simple designs with clean, bold lines. Intricate designs may put your order on hold.
• Thread Colors: You can use any thread color for your design, except metallic or neon. Gradient and multi-color designs are possible.

Important Embroidery Disclaimers

• The preview on the mockup is for visual reference only and may not perfectly match the final result.
• Fine details in flat embroidery use a single row of stitches (run-stitch), and very small letters may be unreadable.
• Elements with less than 3mm between them may be connected by segments of run-stitch or connecting threads, which can be 1.3–3 mm (0.05"-0.19") long, particularly noticeable in text.
• Stitching consistency depends on the material; satin stitch on beanies, for instance, might have more gaps than on a hoodie.
• Minor variations in exact placement can occur due to human involvement in the process.
• Large and heavy embroidery on thin fabrics can sometimes cause slight fabric curving or warping.
• On soft beanie fabric, details done in run-stitch may sink into the material and appear "missing."

Custom Printing for Hats (Direct-to-Film)

Direct-to-film printing is an excellent choice for designs requiring intricate details, multiple colors, gradients, or even photographic images.

Optimal Printing Locations

• Caps:
  • Front: The maximum print area is 5 inches x 2 inches.

Tips for Best Printing Results

• High-Quality Artwork: Submit files in PNG or JPEG format with at least 300 DPI. Create your files in the sRGB color profile. If your graphic's resolution is too low, it's best to create a new one, as simply increasing the resolution won't improve print quality.
• Avoid Semi-Transparent Designs: Semi-transparent graphics or elements with lowered opacity don't translate well in direct-to-film printing. Stick to solid colors, or simulate semi-transparency using halftoning.
• Incorporate See-Through Elements: Adding see-through elements throughout your design can give the print a lighter feel. This reduces the amount of ink and adhesive used, resulting in a softer final product compared to large, solid-color designs.
• Skip Soft Edges: Designs with soft edges don't work well for direct-to-film prints because the small ink dots that create the effect may not adhere properly, leading to a rough, blotchy edge.
• Text and Lines: Ensure all lines are a minimum of 1 pt thick in Adobe Illustrator or approximately 4 px at 300 DPI in Photoshop. Keep all text lines at least 1 pt thick, with font sizes generally between 10–12 pts, depending on the typeface. Consider adding a background color to small text to help prevent peeling.
• High-Resolution Images: Direct-to-film printing excels at reproducing full-color, high-quality images. The higher the image resolution, the clearer and sharper your print will be.

Important Direct-to-Film Printing Disclaimers

• Due to printing specifications, a white color layer may be visible under the color ink layer.
• The print might feel slightly stiff initially but will soften after a few washes. The feel can vary based on the fabric type, and breathability for these prints is relatively low.
• The print might develop small cracks if the garment is washed in hot water.
• We recommend ironing garments inside out, as ironing directly on the print could change its color (e.g., white elements might turn yellow).