Custom Hat & Cap Embroidery — Flat Stitch, 3D Puff & Beanies
Hats are the most demanding surface in embroidery — a curved panel, stiff buckram, a seam through the middle of your design. We digitize and stitch for that surface specifically. Edge Embroidery is a custom embroidery shop in the Scottsdale Airpark serving Scottsdale, Phoenix, Tempe, Mesa, Paradise Valley, and all of Arizona.
Hats We Embroider
- Structured caps — stiff front panel, ideal for logos and 3D puff
- Snapbacks and flat brims
- Dad hats — unstructured, suited to smaller flat-stitch designs
- Trucker hats — foam front, mesh back
- Beanies — knit stretches, so we digitize for it
Bring your own hats or order through our SanMar catalog — Port Authority, Nike, Carhartt, and more, sized for whole teams. Garments purchased through the catalog include free 5″×5″ embroidery.
Placements
Front center is standard. Side panels suit a small secondary mark — a web address, flag, or icon — and back placements above the closure work well for team names. Each placement is its own run, priced per location.
3D Puff Embroidery (+$5)
Puff is foam stitched under the thread, so the design stands off the cap. It requires bold shapes: thick block letters, solid marks, heavy numbers. Thin scripts and fine outlines can’t wrap the foam and won’t hold. Structured caps carry puff best — the stiff panel gives the foam support.
Not sure your logo qualifies? Send it over. If flat stitch is the better call, we’ll say so.
Metallic Thread
Gold and silver metallic thread is +$10 per hat. It runs slower and takes more care on the machine, which is reflected in the price.
Hat Embroidery Pricing
| Item | Price |
|---|---|
| Standard embroidery (up to 5″×5″) | $20 per hat |
| 3D puff | +$5 per hat |
| Metallic thread | +$10 per hat |
| Specialty thread | +$30 per hat |
| Logo digitizing (one-time, file kept forever) | $55 |
| Text/name design setup (one-time) | $10 |
Cap stitch files are digitized separately from flat garments: the curve changes the stitch sequence, underlay, and pull compensation. If we digitized your logo for shirts, a hat needs its own $55 file — once, then it’s on record forever. Details on logo digitizing and pricing.
Small Text on Hats
Text under roughly 4mm tall doesn’t stitch cleanly — thread has physical width, and tiny letters close up. On hats, seams and curvature make the limit stricter. If your design has micro-text, we’ll flag it and suggest a fix before we stitch.
How It Works
- 1. Send your logo at order.edge-az.com or through our contact page.
- 2. We digitize it. One-time $55 cap file, built for the curve, yours forever.
- 3. We stitch — your hats or catalog hats, with USA-made backings and threads.
- 4. Pick up or reorder. Standard turnaround is 7–10 business days; reorders skip digitizing entirely.
Recent work is in the gallery.
FAQs
Can I order just one hat?
Yes — no minimums. One hat gets the same stitch quality as a hundred.
How fast can I get hats?
Standard turnaround is 7–10 business days. Rush service runs 1–5 business days, from +10% for 5-day to +100% for next-day.
Will 3D puff work on my logo?
Bold, chunky designs, yes. Thin scripts and fine lines, no — flat stitch handles detail far better, and we’ll tell you before we stitch.
Do you embroider beanies?
Yes. Knit stretches, so we digitize beanie designs to hold their shape — flat stitch only.
I already paid to digitize my logo for shirts. Why do hats cost another $55?
A cap file is genuinely different — curved surface, different underlay and stitch path. It’s one fee, once, kept forever.
Get Started
Request a quote, call (602) 574-3769, or order online 24/7 at order.edge-az.com. We’re at 7898 E Acoma Dr #102, Scottsdale, AZ 85260 — Mon–Thu 10am–4pm, Fri 10am–2pm.