Zapped Headwear - Frequently Asked Questions
Zapped Headwear specializes in premium custom hats — the kind people actually wear, not cheap throwaway logo hats. We stock over 400,000 blank hats across 300+ variants, offer seven decoration methods including laser-engraved leather patches and 3D puff embroidery, and start custom orders at just 12 hats. Every order includes an online live mockup with your logo or a mockup created by our designers before you buy, and blank hats ordered before 3 PM CST ship the same or next business day.
We hold a 4.9 out of 5 star rating across 268 verified customer reviews.
I don't even have words for how amazing Zapped Headwear is! We ordered 100 hats for our company and was given a 4-6 week lead time (completely understandable, especially since it's the holiday season). To my surprise, our hats were delivered 3 weeks after I placed the order!! They EXCEEDED my expectations..not only on how quickly they finished them but how amazing the hats looks! We did a rubber patch on a black hat and they look incredible! I am extremely happy with my experience using Zapped Headwear and their employees are top notch. Will definitely be ordering from them again in the future! :) - Ashley B.
Zapped Headwear is fantastic! They have great quality hats, great staff, and they helped me crank out a large order last minute. They are awesome and I will definitely be using them again in the future!! - Tyler B.
Very impressed with the quality and prices of the hats! Ordered about 50 waffle beanies w/ the leather patch and they all turned out very well. Customer service was exceptional. I Will be using this company again if I ever need to make any sort of hat! - Jacob H.
Zapped has been amazing. We’ve ordered hundreds of hats through them and they always get done quickly, and look amazing. The quality is just as good as any hat out there and my employees love them. We often get customers asking if they can have one. Highly recommend !! - JJ M.
The hats turned out perfect! I shopped around quite a bit to try to find some leather patch hats that I could get made and delivered in under 3 weeks. I came across Zapped and saw that they had a 2-3 week turnaround time and they were priced better than any other place I saw. The hats were delivered 8 days after I ordered and they turned out exactly like I had imagined! I definitely recommend using them and I will definitely be using them again for future orders. - Joe B.
Laser-engraved and full-color printed leather patches, rubber (PVC) patches, flat and 3D puff embroidery, embroidered patches, silicone heat transfers, sublimated patches, and woven patches.
Yes. We decorate the front, side, and back — patches and embroidery aren't limited to the front panel.
Yes. Leather patch hats use our live mockup customizer: upload your logo, see a live preview, pick your quantity, and check out. For rubber patch and other decoration types, submit the Custom Hat Quote Request Form and a designer will respond within a couple of days.
If you have used an AI image generator (ChatGPT, Claude, Google Gemini or others) to create a hat design mockup or proof please upload it using the Custom Hat Quote & Mockup form or email it directly to our designer at morgan@zappedheadwear.com. When doing so, please include the original logo files in case we need to make any adjustments.
For leather patch hats, just upload your logo in .png format in our live mockup customizer and our designers take it from there. If you would like another decoration type, please upload a vector file of your logo when filling out the Custom Hat Quote & Mockup request form. If your file needs any cleanup before production, we'll let you know.
The Blackhawk, a 5-panel snapback. We also offer the Osprey 7-panel (including an XL for larger heads in both Blackhawk and Osprey), Marine, Cobra, Gunny, and more, plus trucker hats, dad hats, and bucket hats.
Leather Patch Custom Hats - 12 Minimum
Rubber Patch Custom Hats - 50 Minimum (may mix and match hats with same patch)
Custom Embroidered Hats - 25 Minimum / Contact us for Quote
Other Decoration Methods - Contact us for Quote
Completely Custom Hats (colors or models we currently do not offer, custom tagging etc) - 300 Minimum / Contact us for Quote
You can mix and match hats styles and colors within the 50 minimum. The minimums are for the designs/patches.
Pricing is per finished hat and drops with quantity. Leather patch hats run from $28.39/hat at 12 pieces down to $16.75/hat at 100+. Rubber and embroidered patch hats run from $20/hat at 50 pieces down to $16.75/hat at 100+. Embroidered hats run from $22/hat at 25 pieces down to $16.75/hat at 100+. You can mix hat models and colors to reach quantity price breaks. Prices as listed on our site, subject to change.
Blank hats have no minimum — you can order a single hat. If you need a small order of custom hats we would recommend buying them as blank hats and then taking them to a local embroidery or decoration shop to have them decorated. Decorated custom hats through Zapped direct start at 12 hats for leather patch, 25 for embroidery, and 50 for rubber patch.
Leather patches give a classic premium look, are laser-engraved or full-color printed, start at 12 hats, and take 2–3 weeks. Embroidery (flat or 3D puff) gives a traditional stitched look, starts at 25 hats, and takes 3–4 weeks. Both can go on the front, side, or back of the hat. If you want the fastest premium option, leather patch wins on minimum and speed.
Yes, you can mix and match hat styles and colors within the 50 minimum. The minimums are for the designs/patches.
For example, you can order 10 each of 5 different hats of differing colors and styles to achieve the 50 minimum all with the same decoration design.
Yes. We stock over 400,000 blank hats across 300+ variants, with no minimum order. Blank hats run from $24.99/hat down to $12/hat by quantity; mesh-back hats run from $12 down to $6/hat.
In-stock blank hats ordered before 3 PM CST ship the same business day. Hats ordered after the cutoff ship the next business day.
Yes — businesses, sports teams, events, weddings, merch lines, and resellers. Quantity pricing means your per-hat cost drops as the order gets bigger.
Orders can be tracked at the following link:
Please also see expected lead times below.
When an item is out of stock the expected date of re-stocking is listed on the product page for out of stock variants. These are kept up to date by our staff.
You can also sign up to be notified when an out of stock item is back in stock on the product page.
We only take backorders for quantities over 50 hats. Please contact us to make a backorder. We do not accept backorders on items further than 2 weeks out. We can set you up on back in stock alerts via text or email.
Leather Patch Custom Hats - 2-3 Weeks + Shipping
Rubber Patch Custom Hats - 4-6 Weeks + Shipping
Custom Embroidered Hats - 3-4 Weeks + Shipping / Contact us for Quote
Other Decoration Methods - 0-6 Weeks + shipping/ Contact us for Quote
Completely Custom Hats (colors or models we currently do not offer) - 60 to 90 Days / Contact us for Quote
We can rush your order. Rush orders are typically charged a fee of $1.00 per hat per day quicker than our standard expected lead time above.
Ex: 10 leather patch hats 5 day rush (10 standard business days- 5 days) is $5/day x 10hats so $50 to rush 10 custom hats via production.
Ex: 50 rubber patch hats 20 day rush (30 standard business days - 10 days) is $10/day x 50 hats so $500 to rush 50 custom hats via production.
Contact us if you would like to rush an order.
Sample kits are available at the following link:
Blank hats may also be purchased as samples online.
We do not do samples for decoration types with minimum order quantities.
Yes. Our dealer program gives exclusive bulk pricing on custom and blank hats to hat decorators, promotional products distributors, and marketers. Apply using our Dealer Program Application.
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