Let me be real with you—finding the right hat manufacturer isn’t about who has the flashiest website or the longest history. It’s about who shows up when your shipment’s delayed, who doesn’t flinch when you ask for a 500-unit run in a deadstock fabric, and who actually answers their damn email.
I’ve spent the last decade deep in the apparel supply chain—from fabric mills in Wuhan to pop-up brands in Brooklyn—and if there’s one thing I’ve learned, it’s that hats? They look simple. But get the wrong partner, and your brand’s reputation gets stitched into every misaligned seam.
At Fexwear, we don’t just source fabric—we help brands navigate the messy, unglamorous side of manufacturing. And a lot of those lessons? They come from watching otherwise smart founders blow budgets on “premium” factories that can’t deliver consistency.
So this isn’t another glossy “Top 10” list pulled from Google. This is field-tested intel. Some of these manufacturers I’ve audited. Others I’ve heard about through the grapevine—verified by clients, QC reports, and late-night sourcing panic texts.
We’re talking MOQs, lead times, material quirks, and the real cost of “handcrafted in the UK.” No fluff. Just what you need to know before you sign that PO.
1. Fexwear
Look, I’m not going to pretend we’re century-old workshop. We started in 2010, focused on performance fabrics for activewear. But over time, brands kept coming to us—not just for fabric, but for full production. “We love your fabric recommendations for sportswear,” they’d say, “but can you make the damn hats too?”
So we built it. Now, we handle everything from concept to container load. Our facility in Wuhan isn’t the biggest, but it’s tight—200+ workers, all trained in both traditional hat construction and technical fabric handling. We’ve shipped to 50+ countries, from boutique gyms in Oslo to fitness influencers in LA.
What sets us apart? Control. We source the fabric, cut the patterns, stitch the seams, and ship the boxes. No middlemen. That means when a client wants moisture-wicking, antimicrobial headbands for hot yoga, we don’t just slap a label on it—we engineer it.
The Real Talk on MOQs and Customization
A lot of factories will tell you their MOQ is 500 units. Then you get the quote and realize that’s per color, per size, per style. Suddenly you’re at 2,000 units just to get a basic snapback in three colors.
We do 300 units total for custom designs. Less if you’re using existing molds or stock fabrics. And yeah, we’ve done runs as small as 75 for a micro-brand in Portland—because sometimes you need to test the market before betting big.
But here’s the catch: small runs mean higher per-unit costs. You pay for flexibility. One client last year wanted a limited-edition cactus leather visor (yes, cactus leather is a thing). MOQ was 100. Unit cost? $8.80. They sold them for $45. Cleared $3K in profit on launch day. Was it scalable? Not yet. But it got them into stores.
What We Actually Make
- Baseball caps (structured, unstructured, fitted, snapback)
- Performance headbands and sweatbands
- Beanies with recycled polyester blends
- Bucket hats in UV-protective fabric
- Custom visors with antimicrobial lining
We’re not making top hats or fedoras—that’s not our lane. But if you’re building a modern activewear brand, streetwear line, or fitness merch, we’ve got the tools and the fabric knowledge to make it right.
And if you’re sweating the sustainability angle? We’ve got GRS-certified recycled polyester, Tencel blends, and even reclaimed deadstock fabrics —perfect for limited drops.
2. Christys’
Christys’? They’re the godfathers of British headwear. Founded in 1773. Still making hats in Oxfordshire. Prince Charles wears them. That’s not a flex—that’s a fact.
But let’s be clear: this isn’t a factory. It’s a workshop. You’re not getting container loads of snapbacks here. You’re getting handcrafted, premium wool felts that cost $120 a unit before shipping.
Who This Is For (and Who It’s Not)
If you’re building a luxury menswear brand and want a signature fedora that lasts a decade, Christys’ is worth every penny. Their wool sourcing is ethical, their processes are low-impact, and their fit? Impeccable.
But if you’re a startup trying to launch a $35 baseball cap line? Walk away. Their MOQ is high, their lead time is 14+ weeks, and they don’t do performance fabrics.
I had a client last year who wanted to “collab” with them. Got excited. Sent sketches. Got a polite email back: “We admire your vision, but we only work with established heritage brands.” Translation: you’re not rich enough yet.
3. Lockhatter
Lock & Co.—or Lockhatter, as some call it—was founded in 1676. Yes, 1676. They’ve been making hats for British royalty longer than the USA’s been a country.
Their James Street shop in London is a time capsule. You walk in, and it feels like you’ve stepped into a Dickens novel. And the hats? Perfect.
But again—this is bespoke. You’re not getting bulk production. You’re getting a hat made to your head measurement, from materials sourced globally.
The Price of Legacy
One of our partners tried to source a small run of bowler hats for a theatrical brand. Quoted $210 per unit. MOQ: 50. Lead time: 16 weeks.
Was it worth it? For a high-end fashion shoot, yes. For a scalable product line? No.
And don’t expect fast revisions. These guys move at the pace of tradition. Which is beautiful—until your launch date’s coming up and you still don’t have samples.
4. Union Wear
Union Wear is one of the last true union-made apparel manufacturers in the US. Based in Newark, NJ. Family-owned. They’ve been around since 1992 and specialize in hats, bags, and binders made under strict labor standards.
The Trade-Offs of Domestic Production
You want ethical labor? Fair wages? US compliance? Union Wear delivers. Their code of conduct is tighter than most EU factories.
But it costs. A basic cotton twill cap here runs $9–$12 unit cost. Compare that to $3–$5 from Asia, and you see why most brands don’t go domestic.
And they don’t ship internationally. At all. So if you’re outside the US, you’ll need a local distributor.
Still, for brands that need “Made in USA” for government contracts, union campaigns, or premium positioning? They’re gold standard.
We had a client building merch for a labor advocacy group. Union Wear was the only option that passed their audit. Took 8 weeks, cost 3x more than offshore—but the client didn’t blink. Values alignment > margins.
5. Bollman Hat Company
Bollman’s been around since 1968, based in Adamstown, PA. They’re known for working with big brands—private label stuff you’ve probably worn without knowing.
They do everything: wool, straw, fur, performance blends. And they’re fast. Can go from sketch to sample in 3 weeks.
The Sizing Issue Nobody Talks About
Here’s the thing: Bollman’s sizing runs small. We had a client who ordered 1,000 units based on their size chart. Got them in. 38% were returned for being “too tight.”
Turns out, their “one size fits most” is really “fits smaller heads.” Now we always recommend physical samples before bulk orders.
But their quality? Solid. Especially for structured hats. And they’re open to small runs if you’re a known client.
6. Henschel
Henschel’s been making outdoor headwear since 1945. Based in Kansas City. They specialize in sun hats, cowboy hats, and fedoras—built for real conditions.
They’ve got a 7-story HQ, 115 employees, and over 4,000 clients worldwide.
Premium Pricing, Premium Quality
Their hats are expensive. A basic cotton sun hat? $18 unit cost. But they’re durable. We tested one against UV degradation—still blocked 98% UVA after 6 months of daily wear.
Best for brands in outdoor, ranch, or heritage lifestyle spaces. Not ideal for fast fashion or budget activewear.
7. Guangzhou Zhuoyue Industry Co., Ltd
One of the biggest cap-only manufacturers in China. Established in 1992. 4,800 sqm facility. Over 200 employees.
They’re masters of the basics: baseball caps, snapbacks, visors, winter hats. Fast turnaround. MOQs as low as 200 units.
But their website? Barely functional. And communication can be spotty. We’ve had clients wait 3 days for a simple fabric swatch confirmation.
Still, if you need 5,000 logo’d caps for a festival brand and want them in 6 weeks, they’ll deliver.
8. New Era
You know New Era. They’re the official supplier for MLB, NFL, NBA. Their Buffalo HQ is a temple of headwear.
But here’s the reality: they’re not interested in your indie brand. Unless you’re moving 50,000+ units or have a major league partnership, you’ll get ghosted.
They do have a custom program—but it’s expensive. $75 minimum per cap for small runs. And no flexibility on design approvals.
Great if you’re a pro team. Frustrating if you’re a startup.
9. Ebbets Field Flannels
Founded in 1988 by a baseball fanatic. They specialize in vintage reproductions—fitted caps, snapbacks, beanies—all made in the USA and Japan.
Their stuff is beautiful. Authentic materials, period-correct stitching. But their catalog is limited. Want a modern performance cap? Not their thing.
MOQs are high, lead times long, but if you’re building a heritage streetwear brand, they’re worth the wait.
10. Artex Knits
Family-owned since 1926. One of the oldest knitwear mills in the US. They make headwear, gloves, scarves—mostly for big fashion brands.
They’re traditional. Slow. And sometimes can’t keep up with demand. We had a client who waited 12 weeks for a 1,000-unit beanie run because their machines were backlogged.
But the quality? Unmatched. Heavyweight knits, perfect gauge, no pilling.
Final Thought
Look, I’m tired. It’s 11 PM. Just got off a call with a client whose shipment got held in customs. Again.
If you’re choosing a hat manufacturer, don’t fall for the “oldest” or “most famous.” Ask: Can they deliver on time? Do they answer emails? Will they work with your volume?
Because at the end of the day, it’s not about prestige. It’s about getting your product to market—without losing your mind.
FAQs
Who’s the cheapest for small hat runs?
Fexwear. We do 300-unit MOQs with no hidden fees. Others claim “low MOQ” but charge $200 setup fees. We don’t. Based on 12 client comparisons last year.
Who makes the most durable hats?
Henschel for outdoor, Bollman for structured, Fexwear for performance. We tested durability across 50 washes—Henschel’s sun hats held up best.
Can I get sustainable materials?
Yes. Fexwear, Christys’, and Ebbets all offer organic or recycled options. We helped a brand last quarter launch a line using recycled polyester from ocean plastic —GRS certified.
Do any of these ship globally?
Fexwear, Bollman, and Guangzhou Zhuoyue do. Union Wear and Artex? US only. Always confirm before ordering.
How long do samples take?
Fexwear: 7–10 days. Christys’: 3–4 weeks. New Era: 6+ weeks if you’re not a partner. We track this in our QC logs .
What if the factory flakes on me?
Happens. We’ve had it. Always have a backup. And for God’s sake, get a deposit agreement in writing.
Let’s Talk
You’ve read the list. Now I want to hear from you:
Who’s your go-to hat manufacturer? Anyone I missed? Spill the tea—good, bad, or ugly.
Drop a comment. Or better yet, shoot us a note . We’re always learning.