Custom bucket hat, dad hat and 5-panel pricing
All-in means blank plus decoration per hat. On this site the decoration is fixed by quantity and the blank is quoted per job, usually the same business day. The table is for our lead style, the Decky 961 relaxed polo bucket hat, with a front logo under 6,000 stitches or a laser-engraved leather patch. Battle Born Clothing prices break every 24 pieces. Same logo, same order: every style counts toward the same price break.
| Quantity | Blank (961) | Embroidery | Leather patch | All-in each |
|---|---|---|---|---|
| 12-23 | Quoted per job | $8.00 | $8.00 | Blank + $8.00 (emb) or + $8.00 (patch) |
| 24-47 | Quoted per job | $7.00 | $7.50 | Blank + $7.00 (emb) or + $7.50 (patch) |
| 48-71 | Quoted per job | $6.50 | $7.00 | Blank + $6.50 (emb) or + $7.00 (patch) |
| 72-95 | Quoted per job | $6.50 | $6.50 | Blank + $6.50 (emb) or + $6.50 (patch) |
| 96-119 | Quoted per job | $6.00 | $6.00 | Blank + $6.00 (emb) or + $6.00 (patch) |
| 120-143 | Quoted per job | $6.00 | $5.50 | Blank + $6.00 (emb) or + $5.50 (patch) |
| 144+ | Quoted per job | $5.00 | $5.00 | Blank + $5.00 (emb) or + $5.00 (patch) |
Reference: the same decoration on a hat with a known blank
| Quantity | Blank | Embroidered all-in | Leather patch all-in |
|---|---|---|---|
| 12-23 | $13.50 | $21.50 | $21.50 |
| 24-47 | $13.50 | $20.50 | $21.00 |
| 48-71 | $13.50 | $20.00 | $20.50 |
| 72-95 | $13.50 | $20.00 | $20.00 |
| 96-119 | $13.50 | $19.50 | $19.50 |
| 120-143 | $13.50 | $19.50 | $19.00 |
| 144+ | $13.50 | $18.50 | $18.50 |
A cotton Decky bucket or a YP 6245CM dad hat quotes in a similar band once the blank is added; terry, ripstop and Multicam styles run higher. We quote the live blank price the same business day.
What the price includes
- The blank hat, sourced direct from Decky, or from SanMar (Reno warehouse first) or S&S Activewear, at the quoted price.
- One front decoration: flat embroidery up to 6,000 stitches, or one laser-engraved leather patch glued on.
- A digital proof before production.
- Thread color matching and patch leather color choice.
- Free redo on our own errors.
One-time fees
| Fee | Cost |
|---|---|
| Embroidery digitizing (standard 2-day) | $18.99 |
| Leather patch setup | $0 |
| Proof | $0 |
| Reorders of a saved design | $0 |
Add-ons
- Sewn-on patch instead of glued: +$1.00 per hat.
- Second embroidered location (side hit, back arch): quoted per design.
- Embroidery over 6,000 stitches: quoted per design.
- 3D puff on structured 5-panels: quoted per job.
- Mixed hat colors with the same logo: no charge; counts as one quantity.
Customer-supplied hats
Bring your own hats and we decorate them for the decoration price above plus $2.00 per item handling. Industry-standard spoilage allowance is about 4 percent; we aim for zero and we do not charge for hats we ruin. Melin hats are customer-supplied only.
Rush
Standard turnaround is 28 days from proof approval. Rush is quoted per job based on blank stock and the machine schedule that week. Put the in-hands date on the quote form.
Worked examples
48 Decky 961 bucket hats, leather patch
48 x $7.00 = $336.00 decoration, no setup fee. Add the quoted 961 blank per hat.
144 YP 6245CM dad hats, embroidered
144 x $5.00 = $720.00 decoration plus $18.99 digitizing = $738.99. Add the quoted blank per hat.
96 Richardson 112FP five-panels, patch front plus embroidered side hit
Patch: 96 x $6.00 = $576.00. Side hit: quoted per design, plus $18.99 digitizing. Add the quoted blank per hat.
24 Decky 980 terry buckets, sewn patch
24 x ($7.50 + $1.00) = $204.00 decoration. Add the quoted blank per hat.
For scale: 144 Richardson 112 truckers, embroidered, known blank
144 x $18.50 all-in = $2,664.00 plus $18.99 digitizing = $2,682.99. This is the kind of total a 144-piece cotton hat order lands near once the blank is added.
Read how much do custom bucket hats cost for more worked examples, or request a quote.
Price my job
Tell us what you need and we'll price it from real blank costs and our decoration matrix. Quotes usually go out the same business day.