On-site T-shirt decoration has long been a staple at fairs, trade shows, and pop-ups, but custom hat bars are the latest trend in apparel decoration. The demand for headwear is on the rise, and running a hat bar is a great way to break into this growing market and showcase your customization services. With emblems and patches, you stand out from traditional embroidery by offering unique finishes and dimension while creating an interactive experience. Customers can personalize their own headwear in as little as 45 seconds, making the process fast, engaging, and perfect for running on-site hat decoration.
Here’s some helpful tips on how to run a successful hat bar at your next event:
Best Blank Hats for a Hat Bar
The hats you choose are a crucial part of your hat bar’s success. Look for styles that are easy to decorate, on-trend, gender-neutral, and offer plenty of space for customization. The more real estate available, the more likely customers are to add multiple patches.
A top pick is the Otto Cap Foam Trucker Hat, which allows for decoration on the front, sides, and back. With a large print area and multiple color options, it’s a versatile choice for a custom hat bar.
Choosing Patch Designs for a Hat Bar
When designing patches, consider your blank hats, event type, and target audience. Keep up with trends while offering a variety of styles, sizes, and finishes to give customers the flexibility to mix and match. Having different textures—like embroidered, chenille, or leather patches—adds dimension and allows for tiered pricing.
For efficiency, stick to one decoration method—either DTF and screen printed transfers or emblems and patches. If offering both, use separate heat presses to avoid downtime from adjusting temperature settings. Alternatively, pre-apply DTF or screen printed transfers to some hats in advance, allowing customers to add patches to an existing design.
How to Price Items for a Custom Hat Bar
When pricing your custom hat bar, you’ll want to ensure customers feel they’re getting a great value while also maximizing profit. Since every hat is unique, your pricing strategy should have flexibility while still being profitable.
Here’s how to structure your pricing for success:
- Start with a Base Hat Price: Cover your costs and profit upfront so patches can be priced competitively.
- Use an À La Carte Model: Allow customers to personalize freely, with each patch priced separately.
- Price Patches by Size, Not Type: Smaller patches start around $3, mid-size at $5, and premium designs at $7.50+, for example.
- Factor in Event Type & Location: Pricing may need to adjust depending on the audience—boutique pop-ups vs. craft fairs may have different price expectations.
- Highlight the Custom Experience: Customers are paying for a one-of-a-kind creation and experience, making premium pricing (hats ranging $45-$70) a competitive option.
- Account for Overhead: Include vendor fees, equipment costs, and labor in your pricing to keep your business profitable.
Two Presses for Double the Fun, and Efficiency
Expecting a busy event? Bringing two hat presses can speed up production, letting you prep one hat while another is pressing. Since patches take 45-60 seconds to apply, a second press prevents bottlenecks. Plus, the 360IQ® cap press’s auto-open feature ensures you won’t overheat a design while multitasking.
Special Promotion: Get $360 in Savings with 360IQ® Purchase!
Having two hat presses is an efficiency booster for not only running a hat bar, but your everyday apparel decoration business. If you’re looking to add or upgrade, now’s the time! For a limited time, when you purchase a 360IQ® hat press, you’ll receive three promo codes for $120 off an emblem and patch order, totaling $360 in savings. Get set up for your next event—learn more about our promotion.
For expert tips on running a successful hat bar, tune into our Heat Press for Profit Podcast episode below! Want more insights on on-site printing? Subscribe to the STAHLS’ blog for the latest posts and industry updates!