# Fitted Hat Co. | Custom Fitted, Flexfit & Snapback Hats

Custom fitted hats, Flexfit caps, snapbacks and flat bills with 3D puff or flat embroidery. No hard minimum, 28-day turnaround, by Battle Born Clothing.

Canonical: https://fittedhatco.com/

Flexfit fitted caps, flat-bill snapbacks and on-field styles with 3D puff or flat embroidery, from 12 caps to 1,000+. Priced per cap, proofed before stitching, decorated by Battle Born Clothing.

Fitted Hat Co. is a Battle Born Clothing brand. We embroider and patch custom fitted hats, Flexfit stretch-fit caps, snapbacks and flat bills for teams, retail brands, car clubs, gyms, bars and schools. Flexfit, Richardson, YP Classics, Zapped Headwear and New Era make the blanks; we put your logo on them. Our shop in Yerington, Nevada runs two commercial embroidery heads with Rapos thread, has made laser-engraved leather patches since 2020 on an OMTech 80-watt CO2 laser, and is an authorized decorator for Carhartt, Nike and OGIO. Every order gets a digital proof, a 28-day standard turnaround from proof approval, and a free redo if the error is ours. Flat embroidery on a cap runs $7.00 per cap at 24 pieces and $5.00 at 144+, plus the blank; 3D puff is quoted per design.

## Real work from the shop
- Grey Flexfit fitted cap with a multi-color embroidered logo, Battle Born Clothing, Yerington, NV: https://cdn.shopify.com/s/files/1/0576/8767/0982/files/sat-img-3627.jpg
- Olive Flexfit fitted cap with embroidered logo, Battle Born Clothing, Yerington, NV: https://cdn.shopify.com/s/files/1/0576/8767/0982/files/sat-img-3630.jpg
- White Decky flat-bill cap with 3D puff embroidered letters, Battle Born Clothing, Yerington, NV: https://cdn.shopify.com/s/files/1/0576/8767/0982/files/sat-photoroom-20251215-191733.jpg
- Stack of tan Decky flat-bill caps with 3D puff embroidery, Battle Born Clothing, Yerington, NV: https://cdn.shopify.com/s/files/1/0576/8767/0982/files/sat-photoroom-20251216-171528.jpg
- White Decky flat-bill snapback with blue 3D puff letters, Battle Born Clothing, Yerington, NV: https://cdn.shopify.com/s/files/1/0576/8767/0982/files/sat-img-2759.jpg
- White Decky flat-bill cap with tone-on-tone embroidery, Battle Born Clothing, Yerington, NV: https://cdn.shopify.com/s/files/1/0576/8767/0982/files/sat-img-3358.jpg
- Black Decky flat-bill cap with an embroidered Ironbound MFG logo, Battle Born Clothing, Yerington, NV: https://cdn.shopify.com/s/files/1/0576/8767/0982/files/sat-ironbound-mfg-decky-cap.jpg
- Black Yupoong snapback with embroidered lettering on the machine, Battle Born Clothing, Yerington, NV: https://cdn.shopify.com/s/files/1/0576/8767/0982/files/sat-surfmad-yupoong-snapback-embroidered.jpg
- Cap hooped on the embroidery machine under the needles, Battle Born Clothing, Yerington, NV: https://cdn.shopify.com/s/files/1/0576/8767/0982/files/sat-cap-on-machine-needles.jpg
- Video — Embroidered Decky flat-bill cap, Battle Born Clothing, Yerington, NV: https://cdn.shopify.com/videos/c/o/v/d7576303fc87491ea207939f6617abbc.mp4
- Video — Cap embroidery in progress on the machine, Battle Born Clothing, Yerington, NV: https://cdn.shopify.com/videos/c/o/v/fb953a063c4b45b1a3c09c092da237ce.mp4

## In 40 seconds
Fitted Hat Co. is a brand of Battle Born Clothing in Yerington, Nevada. We embroider Flexfit fitted caps, flat-bill snapbacks and on-field styles with flat or three-D puff embroidery, in-house. No hard minimum. Cap embroidery runs eight dollars a cap at twelve pieces and five dollars at one forty-four, on top of the blank, with a one-time digitizing fee of eighteen ninety-nine. Send artwork, a quantity, sizes and colors and you'll usually have a quote the same business day. Twenty-eight days from proof approval.

Video: https://fittedhatco.com/media/explainer.mp4

Video: https://fittedhatco.com/media/hero.mp4

## Why order from us
- Two commercial embroidery heads in our Yerington, Nevada shop (a Happy HCD2-1501 and a YunFu 15-needle) running Rapos thread, with Maggie magnetic frames for caps.
- Laser-engraved leather patches made in-house since 2020 on an OMTech 80-watt CO2 laser, glued with our heat process or sewn on request.
- No hard minimum on embroidery or leather patch. Price breaks at 12, 24, 48, 60 and 80 pieces for embroidery (every 24 for leather patches) from 1 up to 80+.
- Flat cap embroidery from $5.00 per cap at 80+ (up to 6,000 stitches), plus one $18.99 digitizing fee per logo that stays on file for reorders.
- Authorized decorator for Carhartt, Nike and OGIO; blanks sourced from SanMar (Reno warehouse first) and S&S Activewear, plus Zapped Headwear as a dealer and Decky direct.
- Digital proof before production on every order, quotes usually the same business day.
- Standard 28-day turnaround from proof approval. Rush quoted per job.
- Free redo on any error that is ours.
- Ships nationwide from Nevada.

## Bulk fitted and Flexfit cap orders for teams, brands and companies

Most of our fitted-cap work is 48 to 300 caps for a team, a retail brand or a company that already knows the style number. You pick the blank and colors, send a logo, and we return a proof showing stitch count, placement and (for puff) which parts of the logo will be raised. Pricing is per cap with breaks at 24, 48, 72, 96, 120 and 144 pieces. See the full table on the [pricing page](/pricing/).

### Team and league caps (48 to 300+)

Travel ball, adult leagues and school programs usually order the [Flexfit 6297F on-field cap](/products/flexfit-6297f/) or the [Flexfit 6277](/products/flexfit-6277/) in team colors with a 3D puff front logo. Flat embroidery on the front runs $6.50 per cap at 48-59, $5.50 at 60-79 and $5.00 at 80+ plus the blank and one $18.99 digitizing fee. 3D puff is quoted per design because foam height and stitch count change the price. Mixed sizes in one order are fine; we size-sort before packing.

### Retail and streetwear drops (24 to 500)

If the cap is going on a shelf or a product page, the embroidery has to hold up next to national brands. We run Rapos thread, true-to-logo digitizing and clean backing trim. Flat-bill snapbacks like the [YP Classics 6089M](/products/yp-classics-6089m/), [Flexfit 110F](/products/flexfit-110f/) and [Richardson 511](/products/richardson-511/) take puff on the front and flat embroidery on the side or back. A laser-engraved leather patch on a flat bill is $7.50 per cap at 24-47 and $5.00 at 144+, plus the blank.

### Company and crew caps (12 to 96)

Car clubs, gyms, bars and small companies order 12 to 96 caps and usually want one logo, one placement. Flat embroidery at 12-23 pieces is $7.00 per cap plus the blank; at 24-47 it is $7.00. No hard minimum. Read the [cost guide](/guides/custom-fitted-hat-cost/) for worked examples at 48 and 144.

## 3D puff, flat embroidery or leather patch: which one?

### 3D puff embroidery

Foam under the stitches raises the logo off the crown. Best for bold letters, numbers and simple shapes on structured caps. Fine detail, thin lines and small text do not puff well; we usually puff the main shape and stitch the detail flat. [How 3D puff works](/decoration/3d-puff-embroidery/).

### Flat embroidery

The standard. Up to 6,000 stitches on the front panel, priced on the [tier table](/pricing/). Side hits, back arch text and sleeve-style small logos are added placements, quoted per job. [Flat embroidery details](/decoration/flat-embroidery/).

### Laser-engraved leather patch

Full-grain leather engraved on our 80-watt CO2 laser and glued (or sewn, add $4–6 per cap) to the front of a flat bill or fitted cap. No digitizing fee. Patches up to about 2.5 in wide sit flat across a center seam; the seamless [Flexfit 180 Delta](/products/flexfit-180-delta/) takes larger shapes. [Leather patch details](/decoration/leather-patch-flat-bill/).

## Fitted vs Flexfit vs snapback: pick the closure first

### True fitted

No closure, sized to the head (6 7/8, 7, 7 1/8 and so on). New Era fitted styles are quoted per job through SanMar. Orders need a size breakdown up front; see the [sizing chart](/guides/fitted-hat-sizing-chart/).

### Flexfit stretch-fit

Elastic sweatband in two to four ranges (S/M, L/XL and so on). The [Flexfit 6277](/products/flexfit-6277/), [5001](/products/flexfit-5001/) and [6210](/products/flexfit-6210/) cover most orders. Easier than true fitted because two or three sizes fit nearly everyone.

### Snapback

One size, plastic snap closure, the lowest-risk choice for a group you cannot measure. Flat-bill snapbacks ([6089M](/products/yp-classics-6089m/), [110F](/products/flexfit-110f/), [Cobra](/products/zapped-cobra/)) and curved-bill trucker snapbacks ([Richardson 112](/products/richardson-112/)). Our guide on [fitted vs Flexfit vs snapback](/guides/fitted-vs-flexfit-vs-snapback/) goes deeper.

## FAQ
**What is the minimum order for custom fitted or snapback hats?** No hard minimum. The smallest price tier is 12-23 caps. One sample cap is possible at that tier plus the blank and digitizing.

**What if my logo is more than 6,000 stitches?** Every embroidery price covers up to 6,000 stitches. Above that, each additional 1,000 stitches adds $2.00 per piece at 1-11 pieces, $1.50 at 12-23, $1.00 at 24-59, $0.60 at 60-79 and $0.50 at 80 or more, rounded up to the next 1,000. So a 12,000-stitch logo adds $6.00 per piece at 24 and $3.00 at 80 or more. We digitize first and tell you the exact count with the proof before you approve anything.

**How much do custom fitted hats cost?** Decoration is $7.00 per cap at 12-47 and $5.00 at 80+ for flat embroidery, $7.50 to $5.00 for a leather patch, plus the blank. Flexfit and New Era blanks are quoted per job; a Richardson 112 snapback is $20.00 all-in at 48. 3D puff is quoted per design.

**How long does an order take?** 28 days from the day you approve the digital proof. Rush is quoted per job.

**Do you sell New Era hats?** We decorate New Era NE1000 and NE400 caps sourced through SanMar and quote the blank per job with New Era pricing respected. We do not list New Era blank prices.

**What is the difference between fitted and Flexfit?** True fitted caps are sized to the head with no closure. Flexfit caps use an elastic band in two to four size ranges. Flexfit is easier to order for a group. See the guide on fitted vs Flexfit vs snapback.

**Can you do 3D puff embroidery?** Yes, on structured caps. We quote puff per design and show a flat option beside it.

**Why is 3D puff quoted per design instead of from the table?** Foam area and the dense satin stitching that covers it drive stitch count more than logo size does. Quoting from the art keeps the number accurate.

**Can you put a leather patch on a flat bill?** Yes. Laser-engraved leather patches are $8.00 per cap at 1-23, $7.50 at 24-47, then $0.50 less every 24 down to $4.00 at 192+, glued; sewn adds $4–6 per hat. The Flexfit 180 Delta's seamless front takes the largest patches.

**Is there a setup or digitizing fee?** Embroidery: $18.99 once per logo, kept on file for reorders. Leather patches: no setup fee.


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Fitted Hat Co. is a brand of Battle Born Clothing, 3 Pebble Beach Dr, Yerington, NV 89447. Quote: https://fittedhatco.com/quote/