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How to Heat Press Hats

Step 1: Learn How to Size Designs for Hats.

Whether you decorate T-shirts, team uniforms, corporate wear, or fashion apparel, heat applying to hats is a great way to create add-on sales.

Decorating hats with a cap press is a fast and easy process that will make your business profit. To maximize your production, learn the best sizes for the most common hat types.

High Profile Hat

High Profile Hat

Front – 2.25"H x 5"W
Side – 1"H x 3.25"W
Back – 1"H x 2.75"W
Bill – 2"H x 5.50"W

Mid Profile Hat

Mid Profile Hat

Front – 2"H x 5"W
Side – 1"H x 2.50"W
Back – 1"H x 2.75"W
Bill – 2"H x 5.50"W

Low Profile Hat

Low Profile Hat

Front – 1.75"H x 4"W
Side – 1"H x 2.50"W
Back – 1"H x 2.75"W
Bill – 1.75"H x 5.50"W

Low Crown Hat

Low Crown Hat

Front – 1.75"H x 4"W
Side – 1"H x 2.25"W
Back – 1"H x 2.75"W
Bill – 2"H x 5.50"W

Visor

Visor

Front – 1.50"H x 5"W
Side – 1"H x 4"W
Bill – 2"H x 5.50"W

Step 2: Choose a Type of Hat to Decorate

Heat pressing hats goes beyond applying a design on the front of a basic cap. You can heat apply almost any area on the hat, including the back, sides, and brim. Decorate different types of headwear to expand your product offering, wow customers, and increase profit.

  • Knit Hat
  • Beret
  • Kufi
  • Ball Cap
  • Bucket Hat
  • Skull Cap
  • Visor
  • Straw Hat
  • Military Hat
  • Cowboy Hat
  • Beanie
  • Safari Hat
  • Fedora
  • Newsboy
  • Headband Earmuffs

Step 3: Choose What to Heat Apply to Hats

How do you choose which product to heat apply to a hat? Start by considering your decorating market and blank headwear choice. Next, determine what type of heat transfer you’d like to use. We provide custom heat transfers depending on your desired finish and overall budget. Offer good, better, best options to your customers to help clarify costs and showcase your decorating potential.

UltraColor Max
UltraColor™ MAX Direct to Film Heat Transfers

High-quality, Direct to Film transfers at one low cost. Order finely detailed, unlimited colors, and no outlines at one low cost. These direct to film transfers are available by the sheet with a $25 minimum order quantity.

Leather Patches
Leather Patches

Available as genuine or faux leather, help build brand recognition with these custom laser-etched patches. Featuring a rustic yet refined look, choose from a selection of color, shape, and finish options.

FlexStyle® Custom Emblems
FlexStyle® Custom Emblems

Offer premium embossed emblems with FlexStyle. Choose from four texture and dimensional options with full color, high-quality finishes.

3D Embroidered Patches
3D Embroidered Patches

Elevate cap decoration with these dimensional embroidered patches. Choose up to 6 thread colors and create bold, high-end looks that stand out on any hat.

CAD-PRINTZ Full Color Digital Logos
CAD-PRINTZ® Full Color Digital Logos

You can quickly create high-end looks on virtually any fabric or hard-to-decorate item with only a heat press. Forget the limitations of screen printing or embroidery and delve into detailed digital logos!

SimStitch® Letters & Numbers
SimStitch® Letters & Numbers

Gives the appearance of being sewn with a simulated stitch. Choose 2" letters or numbers.

Pre-Spaced Text
Pre-Spaced Text

Available in a variety of CAD-CUT® materials, comes pre-aligned on a carrier for easy placement. Choose 5/8" or 1" letters.

Team Perfect™
Team Perfect™

Combine school names or player numbers with sport-specific images. Order cap designs up to 3.5" in length and up to 2.5" in height.

ZIPP Weed™ Text
ZIPP Weed™ Text

Available in six Thermo-FILM® and Thermo-GRIP® colors , 5/8" and 1" ZIPP Weed letters are affordable and easy to weed.

Videos for Materials, Services & Equipment View All Videos >

Do-It-YourselfMATERIALS

See the latest innovations in CAD-CUT® heat transfer materials and learn tips, tricks, and instructions on creating the best designs possible.

Go To Materials Videos >

Sports DecoratingSERVICES

Learn how to use Stahls' products to start your own T-shirt business. Watch videos on services, accessories and more.

Go To Services Videos >

Heat Printing & SignEQUIPMENT

Find the right heat printing equipment for your business and learn how to keep it running at full capacity.

Go To Equipment Videos >