printing hats

Expand your Business by Printing Hats

Want to make more money and stand out with something other than T-shirts? Printing hats and headwear are extremely profitable in terms of apparel decoration. With the new Hotronix® 360 IQ® Hat Heat Press, you can heat press hats with ease. Ditch the headaches that come with scorch marks! This revolutionary press was designed to incorporate lower and upper heating elements to ensure a perfect recipe for adhesion, especially with our dimensional products. In this post, you will learn about key materials that work effortlessly with the new 360 IQ® Hat press. Learn more below:

  • FlexStyle® Emblems
  • Hat Styles
  • CAD-PRINTZ® Perma-TWILL® & Texture-TWILL®
  • Dimensional Patches
  • Other Methods

FlexStyle® Emblems

Raise your profits with dimensional products, like our FlexStyle Emblems. These unique emblems offer an alternative approach to embroidery with 4 different styles.


Detailed color and textures


Shiny finish with 3D bubble effect


Shiny 3D finish with a “flatter” appearance


Beveled edges for a sharp, refined look

Hat Styles

Five-Panel Hats

Five triangular pieces are sewn together. No visible seam running down the front of the hat.

Six-Panel Hats

Six triangular pieces are sewn together. Unlike the five-panel hat, there is a noticeable seam down the center of the front panel on the hat.

Seven-Panel Hats

Seven-panel hats have a uniqueness about them. The front has a longer flat area and two triangles sewn at the top. This style is becoming a growing trend.

Unstructured Hats

Unstructured hats or “dad caps”, are low profile hats with no additional support behind the front two panels.

Structured Hats

Additional support is found behind the two front panels, also called a fused buckram.

To shop for more hat styles like the trucker hat, fitted cap, and snapback hat check out our blank apparel page.


If you’re not ready to dive into the emblem trend just yet, look no further than CAD-PRINTZ full-color options. You can achieve a premium look for the lowest cost. In order to properly calculate the cost of your logo, check out our Custom Cost Calculator Tool and login to get started.


Achieve this full-color option with only a heat press. The best alternative to embroidery and applique.


If you want a “textured look” applied to your design, this would be the best option.

Dimensional Patches

It’s no secret that patches are an ongoing trend in the hat world. All of our patch options provide a unique solution for your client. These 3 options will stand out on any hat!

Embroidered Patches

Premium embroidered patches include up to 6 thread colors in the price. These are a classic staple for a traditional embroidery look. They pair well on beanies and knitted headwear.

3D Embroidered Patches

This raised option is a perfect representation for major league sports teams or a similar market. The dimension of the stitches look sewn on, but are applied with just a heat press.

Leather Patches

These real, genuine leather patches come in 3 color ways. We love the versatility these bring to apparel, hats, and hard goods.

If you’re new to our dimensional line-up of Emblems and Patches, we strongly encourage you to order a sample kit with all of our products mentioned above. Test them out and see which material is best for your business.

Other Methods

Lastly, some of our tried-and-true decoration methods can still apply to hats. HTV and Screen Printed logos, are great suggestions if you have low order quantities. We suggest if you’re only producing 25 hats or less at a time, to consider one-off decoration like STAHLS’ HTV rolls, or Transfer Express’ UltraColor™ Soft.

To learn more about everything mentioned, be sure to check out the video below so that you can start profiting from printing hats. Once you’ve decided to invest in your new press for printing hats, learn how to use a hat press properly, by checking out this blog post.

Sharing is caring!

8 thoughts on “Expand your Business by Printing Hats”

  1. I have been interested in your printing business products you promote, but all the time you have replied that you DO NOT cover my region.
    Now that is very sad as am your offers are of great interest to me. I hope you can adjust this.

  2. Hi, my name is Mina.
    I have a sewing and quilting business in Halifax. NS, Canada
    Recently I bought a Cricut Maker to add a t shirt business to my existing business.
    I also teaching sewing and quilting to my students. I love what I do, but I would like some new and easy stuff to my business.
    I ma working on my new website at the moment, which will be launch in January.
    Please advise.

  3. Hello Stacy,
    That was a really informative post for expanding business by printing hats.
    I recently came across this blog [] that says about popular decoration methods. What are your thoughts on that?

  4. Hi Cathy, thanks for reading along and reaching out! The post you mentioned is a nice resource for the varying types of hats you can decorate. With regard to the popular decoration methods, we offer both flat & 3D puff embroidered transfers or Cad-Printz full color digital transfers that are mentioned in the post. You can more information about those transfer types here – & If you have any questions, feel free to reach out to our Customer Service team at 800-478-2457 or Thank you!

  5. Hi Chris, thanks for reading along! Yes, sublimation is possible with the Hotronix 360 IQ. Be sure that you have a white, 100% polyester substrate for the best sublimation results. For more information about sublimation transfers, click here or contact our Customer Service team at 800-478-2457. Thanks!

Leave a Reply

Your email address will not be published. Required fields are marked *