Tag Archives: fabric

Most Popular Fabrics Used in Making Hats

The Most Popular Fabrics For Making Hats

If you are a passionate hat collector, you know there are numerous fabrics for hats. A lot of people overlook the materials that their hats are made of, however. You ought to know the fabric your hat is made of because you want to give it the best care. After all, you cannot wash and maintain your nylon hat the same as your polyester hat.

If you have a collection of hats and have no idea what fabric they are made of, this article is what you need. It brings you the most popular fabric used in making hats.

Most Popular Fabrics Used in Making Hats

Popular Hat Fabrics

1. Polyester

Polyester is a synthetic fiber. It is one of the most popular materials used in making hats. Actually, it is the staple fabric in modern hat making. It is made from recycled plastic. Polyester is a darling to hat makers and most hat lovers because it is durable and resistant to water and abrasions. We cannot think of any other fiber that is durable and cheaper than polyester.

The moisture-wicking property of polyester is also excellent. It excellently absorbs sweat from the skin, leaving it dry and comfortable. You would, therefore, enjoy wearing polyester hats all day long during summer.

Polyester is popular in exercise hats, dad hats (baseball caps), and summer hats, thanks to its moisture-wicking properties. 

2. Nylon

Nylon results in thin and lightweight caps suitable for hot summer days. The highly breathable material is made from recycled plastic. It makes the scorching summer days a lot cooler.

One thing you will love about nylon is that it does not shrink. We are often in constant worries of our hats losing their original shape, but nylon hats will eliminate the concern. Nylon hats are also easy to take care of. 

The only problem is nylon is not great at wicking away moisture, but it tries its best.

3. Cotton

Cotton is one of the natural fibers used in making hats. However, a lot of hats are not 100% cotton. Pure cotton is a bit expensive compared to synthetic fibers. For this reason, they are popular in putting embroideries and logos on caps.

The soft and breathable material makes cotton a darling to hat lovers. Besides, cotton is hypoallergenic. With cotton hats, you will never experience skin irritation.

Cotton is also excellent when it comes to controlling moisture and insulation. Their ability to absorb moisture makes it suitable for making the headbands of caps. Unfortunately, cotton is not as durable as synthetic fibers, such as polyester. This is why it is often blended with manufactured fibers to boost its durability.

Most Popular Fabrics Used in Making Hats

4. Wool

A lot of people associate wool with knitted hats such as beanies. They are, however, used for a wide range of other caps. A lot of classic hats are either part wool or are 100% woolen. They are also a standard component of a considerable number of baseball hats. You will also find wool a popular fabric in making berets. 

Wool, however, remains the most suitable fabric for winter hats. They have a higher capability of keeping you warm whenever you step out in those cold winter days. 

Did you know that cashmere is wool obtained from goats? Yes, and it is popular in making fedoras. 

On the downside, a surprising fact is that wool is known to make hair brittle. It absorbs moisture from the hair, leaving the hair dry, lifeless, and fragile. If you love healthy hair, you may want to line your hair with a satin cap before putting on a woolen hat. 

5. Buckram

Have you ever wondered which material is used to make the sturdy brims of hats? Well, buckram is the answer. The stiff material is used to strengthen the visors of baseball hats. They are sometimes used in strengthening the brims of classic hats. Buckram is often concealed with the outer layer of the hat. Initially, buckram was made of lined and sometimes horsehair. Today, cotton is used to make buckram.

Other than buckram, wood is also used to strengthen hat brims. Its use is, however, declining. 

6. Linen

Linen is a natural fiber that is extracted from the flax plant. If you are looking for another natural fiber other than cotton, linen should be suitable for you.

Just like cotton, Linen is very breathable and soft. They are incredibly comfortable and tender on your skin. You are sure to remain relaxed and comfortable during those fiercely hot summer days. Linen hats are also fantastic for spring. 

7. Straw

Straw hats are fashionable in protecting your head from the fierce sun rays during summer. They have also taken the world of fashion by storm. Straw is made of material from different plants and sometimes synthetic fibers.

Some of the plants used in making straw hats include bamboo, wheatgrass, papyrus reeds, and sisal. 

Most Popular Fabrics Used in Making Hats

8. Plastic

Plastic has become a popular component of hats in the past few years. The plastic and retro visors for women have taken over the world of headwear. They are suitable for protecting you from the scorching sun.

A lot of women love retro visors because they come in very many colorful and catchy shades. You are sure to protect your skin during summer while still manage to stand out with the bold colors. Besides, plastic hats are easier to clean than all the other fabrics.



The world of headwear is liberal. Hats are made of a wide range of materials, depending on their purpose. Hat makers will often experiment and introduce new elements like wood. The materials discussed above are some of the popular fibers used in hat making.

Knowing the material used to make hats is vital for any hat lovers. This way, you will know the pros and cons of all the conventional materials. You will, therefore, have an easier time shopping for hats. Looking at the design and the color of the cap is not enough. You ought to know the materials used in the hat manufacture. You cannot take care of a hat effectively if you do not know its components. Always consider the material used to make hats while shopping for them. 

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8 Amazing Branding Styles for Custom Beanies

So, you’ve decided on custom beanies to take your brand to the next level, now what?

There are so many options, styles, fabrics, etc. available when putting together a design for custom beanies. This can get extremely confusing and borderline overwhelming, but don’t worry Delusion MFG can help. A lot.

Wouldn’t it be nice to have a Beanie Branding Cheat Sheet?

Well, that is exactly the topic that I will be covering in this blog. As I will provide you with in-depth looks, information, reference photos, and explanations on 8 branding/styling options for your custom beanies.

This cheat sheet will be your GO-TO for custom beanie branding now and in the future!

As I have discussed in previous blogs, branding for any custom headwear like a 5 panel hat or merino wool beanie is key in the growth of your business. The more we work together and get creative, the more success you will have. The main element that is beneficial here is “free promotion”.

Customers and clients will be happy to wear your apparel because of the great services you provide to them. (It’s all about how valued your customers are). But on the other end, they are providing you a service by promoting your brand for you. It is a WIN / WIN situation.

Fabrics for Custom Beanies

You’ve decided to move forward, but first, we need a base for your beanie. What fabric should you use? You can’t have a beanie without fabric. I will go discuss some of the industry secrets to choosing the right fabric for your beanie. There is a correspondence between branding and fabrics as well!

It is important to recognize your demographics as well as the climate in these situations!

Merino Wool Fabric – Merino Wool is the industry standard in creating a beanie. The soft, classic feel will leave you nice and warm while bringing the classic style to the table. Given the fabric makeup of merino wool, there are many benefits. These benefits for branding are very important to know. This fabric style is sturdy and is the best beanie fabric for a leather patch style of branding as well as more “full” designs. Nothing says classic like a nice leather patch or woven damask label. Don’t worry, I will discuss these soon!

Check out our merino wool beanies here.

Acrylic Thread Fabric – Acrylic fabric is a lighter, smoother alternative to Merino Wool. The tighter knit style of the thread is great for embroidery options as well as cuff fold labels due to thickness being less than Merino Wool. A lightweight option may be the best choice for the beginning of Winter or End of Winter.

Check out our selection of acrylic beanies here.

Acrylic Mixed Thread Fabric – Acrylic mixed fabric combines the thickness of a Merino Wool Beanie with the feel of an Acrylic Thread Beanie. This option also allows for two or more colors to be used. Having this advantage really allows for a cool look for your clients.

See what I am referring to with our acrylic mixed beanies here.

It is important to realize that there are endless options with the fabric style of the beanie. There are no ends to customization and colors. Choose what you believe your customers would enjoy!

Pro Tip: Neutral Beanie colors are most popular in the Fall and Winter Months. More colorful and vibrant options are seen more in the Spring and Summer! But there is never a guideline to follow, be different!

Branding Options for Custom Beanies

I will break down 8 different branding options for your custom beanies to best fit your needs! This is your unofficial/official cheat sheet.

(1) Flat Embroidery – This is a classic style option. With this, the artwork will be embroidered directly onto the cuff (or other position) on the beanie giving a nice, clean look! This is best for more detailed designs with the overall feel of continuity throughout the beanie.

Red & Blue Custom Acrylic Mixed Beanies
Red & Blue Custom Acrylic Mixed Beanies

(2) 3D Puff Embroidery – This is something that is has grown in popularity recently. Your artwork will be embroidered with a raised presentation onto the beanie. The thread will extrude off the fabric and is best used for simple and bold designs.

Red 6 Panel <a href=Hat w/ Raised Embroidery” class=”wp-image-171″/>
Red 6 Panel Hat w/ Raised Embroidery

(3) Woven Damask Label – Another classic styling popular with many companies. You may have seen the classic Supreme logo in this option on almost all their headwear. Your artwork will be woven into a label that will then be stitched onto the beanie.

Woven Label on Custom Green Beanie
Woven Label on Custom Green Beanie

(4) Woven Cuff Fold Label – Take advantage of the entire beanie with this option! Some people like to wear a beanie cuffed, others uncuffed. With this option, you will have a label that goes over the cuff and can display artwork on both sides. When work, either way, you will be able to promote your brand! This is very popular due to the flexibility that can be used in designing the tag / how particular people like to wear their beanie!

Woven Cuff Label on Blue, Yellow, Grey & Green Custom Beanies
Woven Cuff Label on Blue, Yellow, Grey & Green Custom Beanies

(5) Satin Printed Label – Like the woven damask label, this is a tag that is sewed onto the fabric. The main difference is the texture of the tag (smoother, satin feel) while the artwork is printed onto the tag instead of woven into it. This is a great option for more detailed designs.

Satin Printed Label on Black 6 Panel Hat
Satin Printed Label on Black 6 Panel Hat

(6) Front Leather Patch – Ah, old faithful. The leather patch is unanimous with beanies, given its look and feel. With many leather color options to choose from, there are endless possibilities. But how will it look? There are options to deboss (press in) your artwork into the leather. This is done using a metal mold that is then pressed into the leather to create the depth effect. This classic look allows for a patch that will be the same color throughout. Now for those who want their logo to pop, there is another option. This would be debossed leather with Black Ink. The process is the same, but the mold will contain black color in the spots your artwork will be going. This allows for a distinct color difference, making your logo/artwork really stand out!

Leather Patch on Front of 4 Custom Beanies
Leather Patch on Front of 4 Custom Beanies

Debossed Leather Patch with Black Ink

Debossed Leather Patch w/ Black Ink
Debossed Leather Patch w/ Black Ink

(7) Woven Damask Patch – Like the woven label, this is a great option for more detailed artwork with a flat background. The difference is that the edge of this label will be merrow (or raised). This gives the look of an embroidery patch while maintaining more detailed branding within the label.

Woven Damask Patch on Grey Custom Beanie
Woven Damask Patch on Grey Custom Beanie

(8) Embroidery Patch – Classic, huh? The embroidery patch is for less detailed artwork. This option allows for all the artwork (other than the free space in the background) to be raised off the patch. The merrowed edge is a standard in regard to this.

Blue, Orange & Yellow Gold Embroidery Patches
Blue, Orange & Yellow Gold Embroidery Patches

Though I have covered the main branding options, there are so many new styles being created every day. This is truly exciting, as customization has been taken to a new level. The industry will continue to grow and grow alongside you.


Why Believe Delusion MFG

We have seen the results firsthand. We have been involved in the custom apparel industry since 2008, with previous experience in the brand apparel sector and hospitality industry. That’s almost 10 years of experience! We have seen how not only has society and technology continued to change but the growth of the small business. Delusion MFG can proudly say that we continue to team up with business (from big to small) around the world! We gladly lend our hand in helping businesses grow and succeed on the custom apparel spectrum.

Want some inspiration to get you started?  Feel free to check out our Instagram page. Our page shows just a fraction of the products we have created by working with our customers.

Also, make sure to browse our wide selection of products from hats to leather patches and everything in between on our website.