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8 Amazing Branding Styles for Custom Beanies - image ke-atlas-468843 on https://blog.delusionmfg.com

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.

How Many Embellishments are there for Caps

Embellishments For Caps: How Many Are There?

Hats are a fun, unique, and a great way to add a twist to your outfit. It’s also a great accessory to your brand’s identity whether you’re a clothing company, the neighborhood’s favorite coffee shop or part of a sports team.

Even if it is sweltering hot in your home or place of work, you can use a hat to protect your eyes and skin from the sun! This is not to mention the great convenience this offers you on a bad hair day. Certainly, wigs are a hundred times more cumbersome in comparison if you ask us.

Most caps or hats will do just fine while plain or blank, but why not customize your own hat and add a few hat embellishments to make your collection stand out?

The right embellishment on your 5-panel strap back hats, for instance, will transform your outfit from plain to downright stylish and super trendy. For these reasons, here are a few great hat embellishment ideas that you can try to help your brand or personal style stand out even more.

Twill Appliqué or Tackle Twill

Tackle twill was first introduced by R.J. Liebe to be material for American Football players’ pants. Since then, it has evolved into a superb option for adding an attractive, long-lasting decoration on your hats.

Tackle twill offers you a wide range of customization options to make a stronger statement with your cap for your brand or self. It is a less-conventional way for adding patterns to clothing compared to embroidery and screen-printing, which will make your outfit stand out as pretty unique.

Tackle Twill, also known as Appliqué is done by taking a piece of fabric, cutting it out to your desired pattern, then sewing it onto the hat with a twill made of nylon or any other suitable material.


5 panel hat with sublimation printing
Custom Sublimated 5 Panel Hat

Sublimated patterns are currently some of the most innovative processes adopted by the manufacturing apparel and accessories industry. With these, designers freely enjoy virtually endless possibilities. Some of the most detailed designs are able to appear accurately from sublimation printing.

Indeed, there is huge room left for creativity and durability since the experts employ highly inventive ways to transfer the digital artwork over to fabric panels. Rest assured if you’d like sublimation printed hats from Delusion MFG we will definitely craft the most accurate print possible.

The result is the production of those high-quality fabrics, distinctive designs, and beautiful, vibrant colors that you might be familiar with.  For good measure, customers are always free to pick from a vast selection of designs that are accessible at Delusion MFG.

Woven Labels and Patches

There are hundreds of ideas for cap patches that you can get inspiration from Pinterest so you will not have to wear that plain blank cap anymore!

With a robust needle, pair of scissors and thread, you can use a wide selection of woven patches and labels from Delusion MFG to make your cap pop just reach out to us for custom.

If you’re applying the patch yourself, ensure your needle is strong enough to penetrate your blank cap’s material, try not to get pricked while you’re at it too. Sometimes you don’t need a fully custom hat, it is just as simple as sewing the patch or label to your hat!

Embroidered Patches for Custom Hats

If you are looking for a more specific approach for embellishing your hat, consider looking for custom embroidered and iron-on patches.

This option lets you design a high-quality look for your embellishment at a cost-effective rate, regardless of the fine details or colors involved. You get to sketch or use an image of the desired design and use any method to attach them to your cap.

Screen Printing

This is the most common method for decorating custom sweatshirts and T-shirts, but you can also use it to embellish a dijon colored corduroy unconstructed 6-panel hat.

This process involves placing your custom design on a mesh screen, washing it, then set it up on a press, from which ink is passed via the screen onto the cap.

Screen printing is a preferred option when handling a massive amount of custom hats for a club, company or team, and the results are often great, long-lasting, and visible. Ask us any questions about screen printing your custom hats here.

Leather Patches

Leather patches are the best option if you want to make a blank cap stand out. They are commonly used to brand high-end clothing items like jeans, handbags, and leather jackets, but will work just fine on your hat as well.

You can sew anything between a dense leather design to a sleek suede to add a rugged, personal vibe to your cap.

5 panel hat with premium leather patch
Custom 5 Panel Hat w/ Custom Leather Patch


Embroidery takes two primary forms; flat and 3-D. Flat embroidery is where the decorating stitching is done directly on the cap, to bring a flat design. This option is more common owing to its relative ease of application and the ability to create the most detailed designs without ruining the images.

3-D embroidery, on the other hand, uses foam to create the 3-D impression. Foam is inserted under the stitch to raise it off the cap’s surface, thus giving your embellishment that unique look. 3-D embroidery is a better option for embossing alphabets, letters, numbers, or symbols- anything that is not too complicated.


Without a doubt, the above mentioned seven methods to embellish your hats will help you transform your caps, hats, and beanies into highly unique and branded headwear for you, your brand or team.

If you’re thinking of creating your own custom hat with us, be sure to reach out to us here. Take a look at some of our previous custom made hat for our awesome customers if you need a bit of inspiration.