Custom Large 5 Panel Perforated Performance Snapback Golf Hat - 6526L
Designed for comfort, performance, and sustainability, our oversize water-repellent performance baseball hat in Size XL is the perfect choice for individuals with larger head sizes. This premium hat is ideal for retailers, outdoor enthusiasts, and businesses seeking high-quality, customizable headwear.
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NDA Protected
Your designs fully protected
Certified Multi-Step QC
5 Certified QC Standards
Free Sample Available
Sample before bulk order
5 Factory Network
Scalable, Flexible Production
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Flexible Customization for Every Brand Need
Construction & Structure
Embroidery
Most PopularFlat Embroidery
Clean, professional finish for detailed logos and text. Up to 12 thread colors.
High impact3D Puff Embroidery
Raised foam backing for bold, dimensional lettering. Up to 3 colors. Front panel only.
AccentSpecialty Thread
Metallic, reflective, or glow-in-the-dark options. Gold, Silver, Copper and 7 more colors.
Available positions & max sizes
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1.
Front CenterMax 2.4" H × 4.0" WFlat Embroidery 3D Puff Embroidery Specialty Thread
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2.
Left SideMax 1.4" H × 2.8" WFlat Embroidery Specialty Thread
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3.
Right SideMax 1.4" H × 2.8" WFlat Embroidery Specialty Thread
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4.
Back CenterMax 1.2" H × 2.0" WFlat Embroidery
Laser-perforated areas (side and back panels) have limited surface integrity. Embroidery is only applied on solid-fabric zones above the perforation line.
Embroidery Design Tips
- Text should be no smaller than 0.2" tall with a minimum stroke width of 0.08"
- Front panel: max 3 lines of text, 20 characters per line for best clarity
- Side/back: max 2 lines, 10 characters per line due to limited space
- Fine lines, gradients, and shading are difficult to reproduce — use solid fills
- Large solid backgrounds may cause fabric distortion; our team will advise if adjustment is needed
Print on this style
In-house DTF (Direct-to-Film) printing delivers full-color, photo-quality graphics with no color limit. DTF prints are flexible, durable, and can be applied across both smooth and perforated panels.
Unlimited ColorsDTF (Direct-to-Film)
Full CMYK color. Soft hand feel. Ideal for gradients, photos, and complex artwork.
Best for volumeScreen Print
Traditional ink-on-fabric. Best for bold, solid-color designs at volume. Up to 6 spot colors.
Visor onlySublimation (Visor)
Dye-infused, permanent print with zero hand feel. Polyester visor surface only.
Available positions & max sizes
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1.
Front CenterMax 2.4" H × 4.0" WDTF (Direct To Film) Screen Print
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2.
Left SideMax 1.5" H × 3.0" WDTF (Direct To Film)
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3.
Right SideMax 1.5" H × 3.0" WDTF (Direct To Film)
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4.
Back CenterMax 1.2" H × 2.0" WDTF (Direct To Film)
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5.
Visor TopMax 2.0" H × 5.5" WDTF (Direct To Film) Screen Print Sublimation
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6.
Visor UndersideMax 2.0" H × 5.5" WDTF (Direct To Film) Sublimation
DTF can be applied across perforated panels — perforations remain functional beneath the transfer. Screen print and sublimation are not recommended on perforated areas.
File requirements
- Vector files preferred (AI / EPS / PDF)
- High-resolution PNG accepted (300dpi minimum, transparent background)
- CMYK color mode for accurate reproduction
Patches on this style
Patches offer a premium, tactile branding element. We produce woven, PVC, leather, and chenille patches in-house and apply them during production for a clean, factory-finished result.
Detailed LogoWoven Patch
Fine-thread woven fabric. Excellent for intricate logos. Merrow or laser-cut edge.
Outdoor / SportPVC / Rubber Patch
Molded 3D rubber. Waterproof, durable. Up to 8 colors + layers.
PremiumLeather Patch
Genuine or vegan. Debossed, embossed, or laser-etched branding.
Available positions & max sizes
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1.
Front CenterMax 2.5" H × 3.5" WWoven Patch PVC / Rubber Patch Leather Patch
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2.
Left SideMax 1.5" H × 2.5" WWoven Patch PVC / Rubber Patch
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3.
Right SideMax 1.5" H × 2.5" WWoven Patch PVC / Rubber Patch
Patches cannot be applied on laser-perforated panels — solid-fabric zones only. Back center is not recommended due to limited space near the snapback closure.
Print File Requirements
- Vector file required (AI / EPS / PDF) for custom die-cut shapes
- For leather patches, provide a single-color artwork — deboss/engrave is monochrome
- PVC patches: specify Pantone colors for exact color matching
Build This Cap from Scratch
We offer full custom application methods to match your style, budget, and branding goals.
Hat Style & Silhouette
Select a base silhouette or submit your own tech pack. We support structured, mid-profile, and unstructured builds across 5-panel, 6-panel, and 7-panel configurations.
Available Silhouettes
- 5-Panel Camper— Flat or slightly curved visor, low-to-mid crown, classic streetwear profile
- 6-Panel Structured Cap— Traditional baseball shape with buckram-reinforced front panels
- 6-Panel Unstructured— Soft crown, dad-hat feel, relaxed fit
- 7-Panel— Extended front seam for a larger embroidery canvas
- Trucker / Foam Front— Foam front panels with mesh rear; structured or unstructured
Crown & Visor Options
- Crown height: Low (3.25″), Mid (3.75″), High (4.25″)
- Crown structure: Structured (buckram), Mid-structured, Unstructured
- Visor shape: Pre-curved, Flat, Slightly curved
- Visor length: Standard (2.75″), Short (2.25″), Extended (3.25″)
- Visor underside: Matching, Contrast color, Grey, Green (classic)
Design Tips
Not sure which silhouette works best? Send us a reference photo or sketch — our design team will recommend the closest match and create a mockup within 24 hours.
Materials & Fabrics
Choose from our in-stock fabric library or source your own. We work with cotton, polyester, nylon, wool blends, and specialty textiles — woven, knit, and non-woven.
Cotton Twill
Classic, durable, 7 oz weight. Ideal for structured caps with clean embroidery.
Corduroy
Textured cotton blend with retro aesthetic. Wide-wale and micro-wale available.
Recycled Polyester
GRS-certified, moisture-wicking performance fabric. Lightweight and quick-drying.
Performance Mesh
Breathable polyester mesh for rear panels. Multiple hole patterns and weights.
Nylon Ripstop
Tear-resistant, packable. Popular for outdoor and travel caps.
Waxed Canvas
Heavy-duty, weather-resistant finish. Ages naturally for rugged brand appeal.
Wool Blend
Premium hand-feel, warm-season and cold-season weights. Excellent for luxury branding.
Custom / Client-Supplied
Send us your fabric. We'll test feasibility and produce a sample within 7 days.
Fabric Notes
- All fabrics pass OEKO-TEX or equivalent safety testing before production
- Custom fabric orders may extend lead time by 5–10 days for sourcing and testing
- We provide free physical swatches on request before committing
Custom Colors
Match your brand palette precisely. We offer Pantone matching, custom dyeing, and multi-color panel configurations on all full-custom orders.
Color Capabilities
- Pantone Matching: Fabric dyed to your exact Pantone reference (TPX/TCX). Delta E ≤ 1.5 guaranteed
- Multi-Panel Color: Assign different colors to individual panels, visor top/bottom, sweatband, and closure
- Tone-on-Tone: Matching thread, eyelets, snaps, and labels to body color for a premium monochrome finish
- Stock Colors: 20+ ready-to-go fabric colors for faster turnaround (no dye lot lead time)
- Sublimation Print: All-over pattern or gradient prints on polyester base fabrics
Solid
One consistent color across all panels, visor, and closure.
Two-Tone / Split
Different colors for front vs. rear panels, or crown vs. visor.
All-Over Print
Continuous pattern or gradient via sublimation on polyester fabrics.
Custom dyed colors require a minimum of 300 pieces per colorway. For orders under 300 pcs, choose from our stock color range for fastest delivery.
Closures & Hardware
The closure defines the fit experience. Select from snap, strapback, buckle, elastic, and fitted options — each available in multiple material finishes.
Plastic Snap
Classic adjustable. Color-matched or contrast. Standard 7-position sizing.
Elastic Fitted
Stretch-fit with internal elastic band. No exposed closure for a sleek profile.
Nylon Strapback
Woven nylon strap with slide buckle. Clean, minimal aesthetic.
Leather Strap
Genuine or PU leather with antique brass buckle. Deboss branding available.
Metal Buckle
Brass, gunmetal, or silver finish. Premium look with leather or fabric strap.
D-Ring
Woven cotton strap threaded through dual metal D-rings. Utilitarian style.
Velcro
Quick-adjust hook-and-loop. Often used on performance and outdoor styles.
Fitted (No Closure)
Fixed circumference in S/M/L/XL. Clean back profile for all-around branding.
Hardware Finishes
- Eyelets: Matching, contrast, or no eyelets — available in brass, gunmetal, matte black, silver
- Top button: Self-fabric covered, metal, or removed entirely
- Snap color: 12 stock colors; Pantone-matched on 500+ piece orders
Decoration & Secondary Processing
Beyond logo placement, we offer a full range of secondary finishing techniques to give your cap a unique character — from garment washing to laser cutting.
Garment Wash
Softens fabric and fades color for a lived-in vintage feel. Light, medium, or heavy wash available.
Distressing
Frayed visor, ripped holes, abrasion marks. Hand-applied or machine-controlled for consistency.
Laser Perforation
Precision-cut ventilation patterns on side or rear panels. Custom pattern files accepted.
Additional Finishing Options
- Embossing / Debossing: Pressed texture on leather, suede, or PU elements (visor, strap, patch)
- Reflective Elements: 3M reflective fabric panels or piping for safety and nighttime visibility
- Silicone Print: Raised silicone logo application for a tactile, waterproof brand mark
- Enzyme Wash: Cellulose enzyme treatment for ultra-soft hand-feel without heavy color loss
- Pigment Dye: Post-construction dyeing for rich, uneven coloring with vintage character
- Seam Tape: Interior seam taping for a clean inside finish and added durability
Process Note
- Multiple finishing techniques can be combined (e.g., garment wash + distressing + embossed leather patch)
- Some processes may affect embroidery or print quality — our team will advise on optimal sequence
- We produce a finishing sample for approval before applying to bulk
Performance Technology
Integrate functional performance features into your custom cap design. Each treatment is tested and certified to maintain effectiveness through 30+ wash cycles.
Moisture Wicking
Capillary-action fabric treatment pulls sweat away from the scalp. Ideal for sport and outdoor use.
Water Repellent (DWR)
PFC-free durable water repellent coating. Beads water off the surface without affecting breathability.
UPF 50+ Sun Protection
Fabric-level UV blocking rated to UPF 50+. No chemical sprays — woven into the fiber structure.
Anti-Microbial
Silver-ion treatment inhibits odor-causing bacteria in the sweatband and interior lining.
Recycled Content
GRS-certified recycled polyester from post-consumer plastic bottles. Full chain-of-custody documentation.
Laser Ventilation
Precision laser-cut micro-perforations on selected panels for maximum airflow without structural compromise.
Performance treatments can be combined. We provide wash-test reports and certifications for each applied technology upon request.
Labels & Branding
Every touchpoint is an opportunity. Replace all interior and exterior labels with your own branding — from the main label to hang tags and care instructions.
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1.
Main Label (center back)Woven or printed brand label, sewn into rear seam. Max size 60×30 mm
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2.
Sweatband LabelWoven label on sweatband interior. Often used for sizing, brand story, or care info
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3.
Taping PrintCustom printed seam tape with repeating logo or pattern along interior seams
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4.
Under-Visor LabelSmall woven or printed label on visor underside. Popular for secondary branding
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5.
Hang TagCustom die-cut hang tag with string or plastic fastener. Full color CMYK printing
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6.
StickerVisor sticker with sizing, style info, or holographic brand authentication
Label Specifications
Woven Labels
Damask or taffeta weave, up to 8 colors, satin or matte finish
Printed Labels
Full-color CMYK on satin or cotton ribbon. Cost-effective for complex designs
Heat Transfer
Tagless printed label directly onto fabric. Softest hand-feel, no raised edge
Care/Content Labels
Compliant with FTC (US), EU Textile Regulation, or your target market requirements
Branding Tips
- We handle all label artwork setup — send your logo and we'll produce a proof within 48 hours
- Country-of-origin and fiber content labels are included at no additional cost
- For Amazon / retail sellers, we can add UPC barcodes and ASIN labels directly to hang tags
Packaging
From polybag basics to premium unboxing experiences. We offer three packaging tiers to match your brand positioning and retail channel requirements.
Standard
Individual clear polybag with suffocation warning. Packed into master cartons (24–48 pcs). Suitable for wholesale and B2B fulfillment.
Branded Box
Custom printed kraft or cardboard box with tissue paper wrap. Brand sticker seal optional. Ideal for D2C and e-commerce.
Luxury
Rigid gift box with magnetic closure, embossed logo, satin lining, and branded ribbon. For limited editions and high-end retail.
Shipping & Carton Details
Master Carton
5-ply corrugated, 24–48 pcs per carton depending on style
Carton Markings
Custom printed or labeled with SKU, color, size, and quantity
Palletization
Export-grade pallets with stretch wrap for container shipments
Inner Packing
Tissue paper, silica gel packets, and shape-keeper inserts available
Branding Tips
- Branded packaging requires artwork setup — allow 3–5 extra days for production
- Eco-friendly options available: recycled cardboard, soy-ink printing, biodegradable polybags
- We can fulfill directly to your warehouse, 3PL, or individual customers (drop-ship)
Our Production Standards
We combine world-class factory capabilities, uncompromising quality control, and a transparent global supply chain so you can scale your brand with absolute confidence.
Factory
We ensure your headwear is built with absolute consistency, zero compromise, and a highly optimized production timeline.
Quality Control
Every batch undergoes rigorous multi-point testing, including fabric stress tests, panel alignment verification, and meticulous checks.
Supply Chain
From sourcing sustainable materials to managing customs and delivery, our end-to-end supply chain is built for speed and predictability.
From order to delivery
We'll give transparent timelines, flexible MOQs, and multiple shipping options to fit your supply chain.
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Frequently Asked Questions
Find answers to common questions about customization, production, and delivery to help you move forward with confidence.
Do you still have any questions or need help from an expert?
What is the minimum order quantity (MOQ)?
Our standard MOQ is 48 pieces for fully custom orders. For blank stock styles, we ship from as little as 1 piece.
Can I customize the logo and design?
Our standard MOQ is 48 pieces for fully custom orders. For blank stock styles, we ship from as little as 1 piece.
How long does sampling take?
Our standard MOQ is 48 pieces for fully custom orders. For blank stock styles, we ship from as little as 1 piece.
What is the production lead time?
Our standard MOQ is 48 pieces for fully custom orders. For blank stock styles, we ship from as little as 1 piece.
Can I request a sample before bulk production?
Our standard MOQ is 48 pieces for fully custom orders. For blank stock styles, we ship from as little as 1 piece.
What shipping methods are available?
Our standard MOQ is 48 pieces for fully custom orders. For blank stock styles, we ship from as little as 1 piece.
Have a project in mind?
We help you customize and manufacture premium hats that are worthy of your brand on time, and on budget.
Do you have any questions or need help from an expert? Contact Us