Custom Foam Trucker Hats — Send Your Artwork, We Do the Rest

What We Make

• 5-panel foam trucker hat blanks ready for print
• Custom trucker caps and custom mesh hats in brand colors
• Custom trucker hats with patch (PVC, woven, leather)
• Retail add-ons: inside labels, UPC stickers, polybags
• Plain trucker hats for programs that need blanks

Materials & Fit

Our crown uses polyester foam. The mesh is nylon. The closure is a snapback. The look is bold and clear. Logos read well from a distance. Sizes include kids, regular, and XL. Brims can be curved or semi-flat. Rope trim and under-brim prints are optional.

How It Works

1. Send files and brief. AI/PDF/EPS or 300-dpi PNG. Share Pantone codes and quantities.
2. Get a free mockup in 24h. We suggest the best method for your art.
3. Approve photos. We make 1–2 samples and send clear photos or short video.
4. Produce and QC. Normal lead time is 12–15 business days after approval.
5. Ship to you. Door-to-door to the U.S. by air or sea. We also support wholesale trucker hats programs.

Decoration Choices

We pick the method that protects foam and keeps edges sharp.

• Heat transfer hat: DTF or HTV for crisp color and small text
• Screen-printed transfers for larger runs and a classic hand feel
• Sublimation hat heat press on request (we check material first)

Patches & Branding

Want texture or depth? Choose PVC, woven, or leather. We color-match to your brand. Add a printed under-brim and rope trim for a strong shelf look. A small side or back label gives a neat finish.

Artwork Rules

Keep key lines ≥ 0.6 mm and gaps ≥ 0.6 mm. Use Pantone (Coated) for spot colors. Leave a 3–4 mm safe area inside the imprint box. The common front area is about 4.25″ × 2.25″. Foam is heat-sensitive, so we control time, temp, and pressure. The result is smooth edges with no shine.

Use Cases

Resorts can launch summer capsules fast. Events can add sponsor marks in days. Brands can test drops before wider release of custom hats. Teams can add names or numbers for camps and tournaments.

Packaging & Quality

Every trucker cap ships retail-ready. Logos stay aligned. Edges are sealed. We can pre-sort by color or size. We can add UPC stickers and polybags. Before pack-out, we check adhesion and look for shine or scorch. We send final photos for your records.

Lead Time & Shipping

Production is 12–15 business days after photo approval. Air DDP is best for firm deadlines. Sea DDP works for planned seasonal orders. We can stage deliveries for multi-drop campaigns. Reorders are easy because we save your settings.

Who It’s For

• Resorts, events, and retailers who need fast proofs and steady quality
• Distributors running private-label wholesale trucker hats with repeat colors
• Teams and creators who want a low MOQ and a quick launch

FAQs

Can you print fine detail or gradients?
Yes. DTF handles small text and soft fades well. We confirm this in the photo stage.

Can I add names or numbers?
Yes. We use HTV or segmented DTF. Send a spreadsheet.

Do you offer kids and large sizes?
Yes. We stock kids, regular, and XL.

My art is a JPG. Is that OK?
Yes. Send it. We will advise if a quick vector clean-up is needed.

Can I mix blanks and decorated in one PO?
Yes. Combine plain trucker hats and printed caps to hit price tiers.

Do you offer PFAS-free options?
Yes. Ask and we will use PFAS-free materials when possible.

Ready to launch? Get pricing for custom foam trucker hats today. Email support@mycustomheadwear.com with your art, quantity, colors, and in-hand date. We send a free 24-hour mockup.

Provide Pantone codes for exact color matching. Pantone Matching System (PMS) helps us hit your brand colors.

Vector files print cleaner than low-res images. Learn why here: vector vs. raster artwork .

For full-color logos we often choose DTF. See what DTF transfers are .