Hats 101
HATS 101
You don’t need to be a fashion designer to customize your own hat, but a little knowledge on the subject will definitely come in handy. Time to learn what makes up a hat, as well as the fun process of customizing and ordering.
Still have a question? Let's chat!
Click on our interactive feature to ask us anything.
How to Order
Step One
PICK A PRODUCT. There are a handful of products to consider, like Hats, Visors, Buckets and Cold Weather Knits. And within each there are various silhouettes, like Stretch-Fit, Ultra-Fit, Cuffed Knit and more.
Step Two
CHOOSE SILHOUETTE OPTIONS. There are various options based on the silhouette you choose; potential options include 5-Panel or 6-Panel, traditional/low crown or high crown, visor shape and more.
Step Three
FIND YOUR FABRICS AND COLORS. We've yet to meet anyone who doesn't truly enjoy this part. Choose from numerous fabric and color combinations.
Step Four
DECIDE YOUR EMBELLISHMENT LEVEL. This is a fun part of the process. Raised embroidery, woven label or a screen printed leather patch are just some of the options available which determines your embellishment level.
Step Five
PICK ADDITIONAL UPGRADES. Based on your silhouette, select custom add-ons like piping, cut and sews, specialty visor stitching, beanie pom and more.
Step Six
ADD FREE CONTRAST COLOR OPTIONS. Interchange fabrics, visor options, stitching and more by the dozen.
Anatomy of a Hat
5-Panel or 6-Panel
A 5-Panel hat's front seam stops near the top of the hat. On a 6-Panel hat the front is two separate panels.
5-PANEL
6-PANEL
High Crown, Mid Crown or Low Crown
A high crown hat has a taller and more squared peak.
A mid crown hat has the perfect balance between depth and slope.
A low crown hat has a less steep angle and fits closer to the head.
Structured, Unstructured, Half Structured or Foam Backed
A structured hat's front panels are backed with buckram, making them stiff and sturdy.
An unstructured hat's front panels are just fabric, so they have a more relaxed "dad fit" to them.
A half structured hat's front panels are backed with a plastic mesh structure. Available only on a 5-Panel Adjustable Hat.
A foam backed hat's front panels are lined with foam and typically paired with poly material.
Standard Hat
ADJUSTABLE
Adjustable hats have a mechanism on the back to adjust the size and fit of the hat. They also have an opening in the fabric above the mechanism.
STRETCH-FIT
Stretch-Fit hats have no mechanism to adjust the size of the hat and have closed backs, with no opening.
ULTRA-FIT
Our Ultra-Fit hats combine the best of an Adjustable and Stretch-Fit hat by utilizing our four-way stretch A-Flex Sweatband.
Specialty Silhouettes
BOONIE
SMALL BRIM BUCKET
LARGE BRIM BUCKET
REILLEY
LOW CROWN VISOR
HIGH CROWN VISOR
Knit Techniques
Here is a small sampling of popular knit techniques used on our Cold Weather Knits.
FLAT KNIT
RIBBED KNIT
WAFFLE KNIT
CABLE KNIT
Fabric & Color
Download our complete Fabrics & Color Guide
The most comprehensive guide to our entire offering.
Options
FLAT EMBROIDERY
RAISED EMBROIDERY
RAISED & FLAT EMBROIDERY
FLAT EMBROIDERY
WITH TEXTURED PEARL FILL STITCH
+ Upgrade Cost
RAISED EMBROIDERY
WITH TEXTURED PEARL FILL STITCH
+ Upgrade Cost
RAISED & FLAT EMBROIDERY
WITH TEXTURED PEARL FILL STITCH
+ Upgrade Cost
FLAT EMBROIDERY
WITH DIAGONAL STITCH
+ Upgrade Cost
RAISED EMBROIDERY
WITH DIAGONAL STITCH
+ Upgrade Cost
RAISED & FLAT EMBROIDERY
WITH DIAGONAL STITCH
+ Upgrade Cost
FLAT EMBROIDERY
WITH RHINESTONES
+ Upgrade Cost
WOVEN LABEL
WOVEN LABEL
WITH EMBROIDERY
EMBROIDERY
ON WOVEN LABEL
SINGLE-PIECE DIE CUT PATCH
+ Upgrade Cost
TWO-PIECE DIE-CUT PATCH
+ Upgrade Cost
SINGLE-PIECE DOUBLE LAYER FELT PATCH
+ Upgrade Cost
SINGLE-PIECE
DIE-CUT PATCH
WITH EMBROIDERY
SUBLIMATED PATCH
+ Upgrade Cost
EMBROIDERY ON SUBLIMATED PATCH
+ Upgrade Cost
SCREEN PRINT
ON LEATHER PATCH
+ Upgrade Cost
SCREEN PRINT
ON SUEDE PATCH
+ Upgrade Cost
LASER ETCHED
LEATHER PATCH
+ Upgrade Cost
REVERSE LASER ETCHED
LEATHER PATCH
+ Upgrade Cost
LASER ETCHED
SUEDE PATCH
+ Upgrade Cost
REVERSE LASER ETCHED
SUEDE PATCH
+ Upgrade Cost
FLAT EMBROIDERY ON VELCRO PATCH WITH REMOVABLE EMBROIDERY ON FABRIC PATCH WITH MERROWED EDGE
+ Upgrade Cost
FLAT EMBROIDERY ON VELCRO PATCH WITH REMOVABLE WOVEN LABEL WITH MERROWED EDGE
+ Upgrade Cost
1-COLOR BONDGO
+ Upgrade Cost
2-COLOR BONDGO
+ Upgrade Cost
BONDGO WITH EMBROIDERY
+ Upgrade Cost
1-COLOR BONDGO ON FABRIC PATCH
+ Upgrade Cost
SCREEN PRINT ON
1-COLOR BONDGO PATCH
+ Upgrade Cost
WOVEN CLIP LABEL
SCREEN PRINT ON
CANVAS CLIP LABEL
+ Upgrade Cost
SCREEN PRINT ON
SUEDE CLIP LABEL
+ Upgrade Cost
LASER ETCHED
SUEDE CLIP LABEL
+ Upgrade Cost
REVERSE LASER ETCHED
SUEDE CLIP LABEL
+ Upgrade Cost
No matter what shape or size, build your own patch in three simple steps. First, pick the ideal embellishment option for your logo. Next, pick which type of fabric to build your patch out of and finally, finish it off with a finishing stitch.
Step 1 // Select an Embellishment Option
Available in Standard, Dull, Neon or Metallic Thread
FLAT EMBROIDERY
RAISED EMBROIDERY
RAISED & FLAT EMBROIDERY
FLAT EMBROIDERY WITH TEXTURED PEARL FILL STITCH
RAISED EMBROIDERY WITH TEXTURED PEARL FILL STITCH
RAISED & FLAT EMBROIDERY WITH TEXTURED PEARL FILL STITCH
FLAT EMBROIDERY WITH DIAGONAL STITCH
RAISED EMBROIDERY WITH DIAGONAL STITCH
RAISED & FLAT EMBROIDERY WITH DIAGONAL STITCH
SCREEN PRINT
Not Available on Velcro Patch
+ Upgrade Cost
Step 2 // Select a Fabric Option
COTTON TWILL PATCH
CANVAS PATCH
Available in Black, White or Stone
FABRIC PATCH
Not Available in EcoPique´, Jersey Fleece, Poly, Performance Wick, Stretch Twill or Stretch Wool
FELT PATCH
SPECIALTY FABRIC PATCH
Not Available in Aloha, Boucle Tweed, Hawaiian, Horsetail, Plumeria or Tie-Dye Specialty Fabrics
VELCRO PATCH
Available in Black, White, Khaki or Olive
Step 3 // Select a Finishing Stitch Option
Available on Cotton Twill, Canvas, Fabric, Felt, Leather, Suede, Specialty Fabrics, Velcro & Woven Labels
JUMP STITCH
SATIN STITCH
RAISED SATIN STITCH
MERROWED EDGE WITH JUMP STITCH
ZIG-ZAG STITCH
FLAT LOCK STITCH
TWO-PANEL SCREEN PRINT
Maximum of 4 Screen Print Colors / 1 Design per Look
+ Upgrade Cost
SINGLE-PANEL SREEN PRINT
Maximum of 4 Screen Print Colors / 1 Design per Look
+ Upgrade Cost
VISOR SCREEN PRINT
Maximum of 4 Screen Print Colors / 1 Design per Look
+ Upgrade Cost
UNDERVISOR SCREEN PRINT
Maximum of 4 Screen Print Colors / 1 Design per Look
+ Upgrade Cost
SUBLIMATION PRINT
Unlimited Colors on Select White Fabrics / 1 Design per Look
+ Upgrade Cost
ALL OVER SUBLIMATION PRINT
Unlimited Colors on Select White Fabrics / 1 Design per Look
+ Upgrade Cost
MULTI-PANEL GRAPHIC
+ Upgrade Cost
HEAVY WASH
+ Upgrade Cost
EXTREME WASH
+ Upgrade Cost
VINTAGE DYE
Available in Cotton Twill on Adjustable Hats Only
+ Upgrade Cost
PERFORATED PATTERN // SIDE PANELS
Available in TriTech on Adjustable, Stretch-fit or Ultra-Fit Hats
+ Upgrade Cost
PERFORATED PATTERN // SIDE & BACK PANELS
Available in TriTech on Adjustable, Stretch-fit or Ultra-Fit Hats
+ Upgrade Cost
2-PANEL PIPING
Available on Adjustable, Ultra-Fit or Stretch-Fit Hats
+ Upgrade Cost
4-PANEL PIPING
Available on Adjustable, Ultra-Fit or Stretch-Fit Hats
+ Upgrade Cost
5-PANEL PIPING
Available on Stretch-Fit Hats Only
+ Upgrade Cost
DOUBLE CONTRAST STITCHING
FREE Upgrade
BASIC VISOR STITCHING
FREE Upgrade
SPECIALTY VISOR STITCHING
+ Upgrade Cost
VISOR BINDING
Add to any Adjustable Hat, Stretch-Fit Hat, Ultra-Fit Hat or Low Crown Visor
+ Upgrade Cost
SANDWICH VISOR
Available in Cotton Twill or Select Specialty Fabrics on Adjustable Hat, Stretch-Fit Hat, Ultra Fit Hat or Low Crown Visor
+ Upgrade Cost
SANDWICH VISOR WITH WOVEN LABEL
Available in Cotton Twill or Select Specialty Fabrics on Adjustable Hat, Stretch-Fit Hat, Ultra Fit Hat or Low Crown Visor
+ Upgrade Cost
VISOR EMBROIDERY PATTERNS
+ Upgrade Cost
TWO CUT & SEW STRIPES
Available in Cotton Twill or Select Specialty Fabrics on Trucker Mesh or Tech Mesh
+ Upgrade Cost
DOUBLE VISOR CUT & SEW WITH BINDING
+ Upgrade Cost
VISOR CUT & SEW
+ Upgrade Cost
VISOR CUT & SEW WITH PIPING
+ Upgrade Cost
DOUBLE VISOR CUT & SEW
+ Upgrade Cost
DOUBLE VISOR CUT & SEW WITH PIPING
+ Upgrade Cost
VISOR CUT & SEW
+ Upgrade Cost
VISOR CUT & SEW WITH PIPING
+ Upgrade Cost
FULL VISOR CUT & SEW WITH DOUBLE PANEL CUT AND SEW
+ Upgrade Cost
PLASTIC SNAP
VELCRO
METAL SLIDER
PLASTIC BUCKLE
RECYCLED PLASTIC SNAP
Available in Black, Charcoal, White or Navy
+ Upgrade Cost
ELASTIC LOOP WITH VELCRO
Available in Black or White
+ Upgrade Cost
METAL BUCKLE
+ Upgrade Cost
LEATHER STRAP
Available in Black, Brown or Tan
+ Upgrade Cost
Washing Guide
Pukka hats can be washed in either your dishwasher (remove before drying cycle) or in your washing machine (remove before spin cycle.) Let all hats air dry. Prior to washing, we recommend you use a hat wash rack.
Our sun hats can be washed in the top rack of your dishwasher, but remember to take it out before the drying cycle starts. Let the hat air dry.
All Pukka knit products should be hand washed in cold water; use a small amount of gentle detergent if necessary. Do not bleach, wring out, or stretch. Gently reshape if needed, then let your knit air dry while flat, and Voilà!