Hat Size Chart & Placement Guide
Cap & apparel sizing plus exactly where your logo can go: standard placements and maximum embroidery sizes. No minimums; design and preview online.
Get the fit and the logo placement right the first time. Here’s how our caps and apparel size up, exactly where your art can go, and the typical embroidery dimensions for each spot, built from 28+ years on the machines.
Hat & cap sizing
Most of our caps are one-size adjustable (snapback, velcro, or flex fit) and fit almost everyone. Fitted and youth styles use the measurements below. To measure: wrap a soft tape around your head just above the ears and across the mid-forehead.
| Size | Head circumference | Best for |
|---|---|---|
| One Size / Adjustable | 54–62 cm (21¼–24⅜”) | Snapbacks, trucker, dad caps (most styles) |
| S/M (fitted) | 55–58 cm (21⅝–22⅞”) | Fitted & flex-fit caps |
| L/XL (fitted) | 58–61 cm (22⅞–24″) | Fitted & flex-fit caps |
| Youth | 52–55 cm (20½–21⅝”) | Kids & smaller frames |
| Beanie | Stretch (one size) | Cuffed & uncuffed knit |
Not sure? Adjustable styles are the safe choice. They flex across the whole range.
Apparel sizing
Apparel (tees, polos, hoodies, jackets) runs true to standard US unisex sizing unless the product page notes a “ladies” or “youth” cut. Brands vary slightly: Port & Company, Sport-Tek, Nike, and Carhartt each have their own chart, so check the size chart on the individual product page. When you’re between two sizes on heavyweight or embroidered garments, size up.
Where your logo can go
You choose placement right in the online designer: front, back, sides, sleeves. Here are the standard locations and the typical maximum embroidery size for each. Larger or wrap-around placements are available on request.
Caps & hats
- Front center: up to 2¼” × 4½”popular
- Left / right side: up to 2″ × 2½”
- Back: up to 1¼” × 4″ (above the closure)
Shirts, polos & jackets
- Left chest: up to 4″ × 4″popular
- Full front: up to 10″ × 12″
- Full back: up to 12″ × 14″
- Sleeve: up to 3″ × 3½”
Beanies & bags
- Beanie cuff: up to 2″ × 3½”
- Bag front: up to 5″ × 8″
- Bag pocket: up to 3″ × 3″
Embroidery vs. print
Embroidery
Our signature: durable, premium, and dimensional. Ideal for logos, monograms, and text on caps, polos, and heavyweight apparel. Best for designs up to a few thread colors.
Print / transfer
Great for full-color artwork, gradients, and large designs on tees and lightweight apparel where dense stitching would be too heavy.
Not sure which suits your art? Add it in the designer and we’ll confirm the best method for your order, or ask us for a recommendation.
Ready to see it on your gear?
Design online in minutes. No minimums, and a free physical sew-out before production on orders $250+.