How To Sell Print On Demand Hats For Profits in 2025

Print-on-demand hats are a golden ticket for entrepreneurs looking to break into eCommerce without breaking the bank. Why hats? They’re the perfect blend of fashion, functionality, and self-expression, making them a year-round bestseller for all kinds of audiences.

In this guide, we’ll dive into the nuts and bolts of building a profitable print-on-demand hat business. Ready to learn the ropes? Let’s dive in and turn your ideas into profits—one hat at a time!

Is Custom Printing Hats Profitable?

Absolutely! Custom printing hats is not just profitable—it’s a thriving business opportunity in 2024. The global headwear market is projected to reach an impressive $24.9 billion by 2025, driven by the growing demand for sports, fashion, and personalized hats. This means there's a massive, diverse market waiting for your creativity and entrepreneurial spirit. Here’s why venturing into custom-printed hats makes financial sense:

Customers today crave uniqueness. Customization options, like embroidered initials or unique color combinations, allow you to cater to this demand for one-of-a-kind products. Personalized hats don’t just sell—they create loyal customers willing to pay a premium for something that reflects their style.

Sustainability is becoming a non-negotiable factor for many consumers. Offering eco-friendly materials and ethical manufacturing practices can help you tap into this growing segment and differentiate your brand. Hats made from organic cotton or recycled materials, for example, attract socially conscious buyers.

The print-on-demand (POD) model minimizes upfront costs, as you only produce hats when an order is placed. This reduces inventory risks and ensures you’re not left with unsold products. Plus, custom hats often carry higher price points, enabling generous profit margins.

How To Sell Print-On-Demand Hats

Step 1: Choose a platform & Build an online store 

When selling print-on-demand hats, the first thing you need to do is select the right platform to sell from. You’ve got two main options: eCommerce marketplaces or dedicated eCommerce platforms. But what's the difference?

eCommerce Marketplace:

Think of an online marketplace like Etsy or eBay as a virtual marketplace where sellers gather to showcase their products to a constant flow of shoppers. 

You list your products, optimize your listings with targeted keywords, and wait for customers to find you. While it’s a quick and easy way to reach potential buyers, you have limited control over the shopping experience and branding.

eCommerce Platform:

An eCommerce platform like Shopify or WooCommerce allows you to create your standalone website. This gives you full control over how your brand looks, how customers interact with your site, and the overall shopping experience. You can integrate it with a print-on-demand service to offer custom hats, giving you more freedom to build a personalized, engaging, and professional online store.

Once you’ve picked your platform, you can start building your online store. Most platforms have apps that make it super easy to customize your website’s design, so you don’t need to be a tech genius. 

For example, Shopify offers page builder apps like EComposer, which gives you ready-made templates, unique elements, and powerful features to create a stunning website. You can also explore apps like EcomRise Upsell & Bundles to boost sales through attractive offers.

If you're new to Shopify, you're in luck! Shopify offers a special deal - 1 dollar for 3 months plan: you can start your store and use it for just $1 for 3 months. It’s a great way to get a feel for the platform without breaking the bank.

Choosing the right platform and building your online store is the foundation of your print-on-demand business. With a solid platform, you’ll be ready to focus on other aspects like marketing and product design. 

Step 2: Choose your product & Find your target audience

Before diving into product selection, it’s crucial to define your brand and its core message. What does your brand stand for? What message do you want your products to convey? Answering these questions will help you narrow down your niche, identify your ideal customers, and create designs that resonate with them.

Your audience is the heartbeat of your business. Are they fashion enthusiasts, outdoor adventurers, or perhaps sports fans? Understanding your audience will guide your product choices and design styles. Consider factors like:

• Age group: Are you targeting teenagers, young adults, or professionals?
• Interests: Do your customers care about trends, sustainability, or customization?
• Style preferences: Will your audience prefer minimalist designs, bold patterns, or witty slogans?

Once you know your audience, think about the designs they’d love to see on these hats. For example, nature-themed prints might appeal to outdoor lovers, while funny slogans could draw in a younger crowd. Aligning your products with your brand vision ensures a cohesive and appealing lineup. Defining your niche and selecting the perfect products is a key step in setting your store apart. 

Step 3: Find a reliable supplier

The success of your print-on-demand hat business hinges on finding a dependable supplier who can deliver high-quality products and seamless service. A reliable supplier not only ensures that your hats meet customer expectations but also streamlines your business operations, leaving you more time to focus on growing your brand.

Here are a few things that make a top dropshipping and hat printing service provider:

• High-quality printing to ensure your designs look professional and vibrant.
• Wide product selection, including various hat styles to suit diverse customer preferences.
• Easy integrations with popular eCommerce platforms like Shopify, WooCommerce, and Etsy make it simple to connect your store with their services.

With a reliable supplier, you can quickly integrate your online store and start fulfilling orders with ease. Their user-friendly platform takes the hassle out of managing inventory and shipping so you can focus on building your brand, marketing, and engaging your customers.

Step 4: Design your products

Now comes the creative part: designing your hats! This step allows you to bring your brand’s personality and message to life through eye-catching visuals and unique designs. You have three options: 

• Create your designs using graphic design tools like Canva, Adobe Illustrator, or Photoshop. These tools allow you to craft unique, professional designs tailored to your brand.
• Hire a freelance designer if the design isn’t your strong suit. Platforms like Fiverr or Upwork have plenty of skilled professionals who can bring your vision to life.
• Use pre-made designs or design templates provided by your supplier. This is a quick and easy option if you want to get started right away.

Uploading your designs is typically a straightforward process with print-on-demand suppliers. Once uploaded, preview how your designs look on different hat styles to ensure they meet your expectations.

Read more: Top 15 Best Design Clothes Apps For Sustainable Fashion Designers.

Step 5: Fulfill your order

One of the best things about running a print-on-demand hat business is how streamlined the fulfillment process can be. Once a customer places an order, the entire process is handled for you by your supplier—saving you time and effort.

• Order is placed: A customer purchases a hat from your online store.
• The supplier gets to work: Your print-on-demand supplier prints the design onto the selected hat, ensuring it matches the quality and style you’ve promised.
• Packaging and shipping: The supplier packages the hat and ships it directly to your customer.

This automated process eliminates the need for you to manage inventory, worry about storage, or deal with shipping logistics. It’s a hassle-free way to ensure customers get their orders on time while you focus on marketing, designing, and growing your business.

Best-Selling Custom Printed Hats

Bucket Hats

Bucket hats are a fashionable staple with broad appeal, making them a favorite among various audiences. With endless design possibilities, they can easily cater to diverse customer preferences.

Supplier costs for bucket hats range from $3 to $10 per unit, depending on materials and design complexity. Market prices, on the other hand, fall between $15 and $35, offering potential profit margins of 40% to 80%. Trendy or exclusive designs can drive even higher profitability.

Google Trends data shows that bucket hats remain consistently popular, with demand peaking between April and July, aligning perfectly with the summer fashion season.

Fedoras

Fedoras are a timeless accessory that appeals to a diverse audience. Supplier costs typically range from $5 to $15 per unit, depending on the quality and materials used. In the market, fedoras sell for $20 to $50, influenced by factors like brand, design, and perceived value. This creates an attractive profit margin potential of 25% to 70%.

These hats are also ideal for creating branded collections and targeting niche markets, making them a versatile choice for businesses. Plus, Google Trends consistently shows strong demand for fedoras, reinforcing their popularity year-round.

Baseball Caps

Baseball caps enjoy steady demand year-round, making them a reliable choice for sellers. Supplier costs range from $2 to $10 per unit, depending on the materials and brand, while market prices typically fall between $10 and $30, influenced by brand reputation, design, and added features.

This creates profit margins of 30% to 70%, with branded or specialized caps offering the potential for even greater returns. While demand slightly dips during the winter months, baseball caps remain a popular accessory throughout the year. See also Google Trends Data.

Berets

Berets cater to a niche market, making them ideal for targeted advertising campaigns. Supplier costs range from $5 to $20 per unit, depending on the materials and craftsmanship, while market prices typically range between $15 and $40.

For dropshipping print-on-demand berets, profit margins generally fall between 40% and 60%, with premium or artisanal designs offering even higher returns. According to Google Trends, demand for berets is consistent year-round, peaking in October, making it a strategic product to market during the fall season.

7 Best Print-on-Demand Hats Companies

1. Printful

Printful offers a diverse range of print-on-demand products and features designed to help you launch and scale your business. From apparel and home décor to accessories, its extensive catalog provides plenty of options. Printful also includes helpful design tools like a T-shirt mockup generator and logo maker, making it a versatile platform for entrepreneurs.

Outstanding Features:

• Custom branding options for products and packaging, including inside labels and packaging inserts.
• Additional services include graphic design and marketing video creation.
• Bulk discounts of up to 30% are ideal for larger orders.
• User-friendly tools like a T-shirt mockup generator and logo maker for a streamlined design.

Website: printful.com

2. Printify

Printify boasts the largest catalog of custom products and connects users with a global network of printing partners. This allows merchants to choose products and local producers for faster, more cost-effective shipping. As a vendor network, Printify sources and prints products through worldwide partners, giving users a wide variety of customization and fulfillment options.

Outstanding Features:

• Extensive catalog of customizable products across multiple categories.
• Global printing network for localized production and faster shipping.
• Diverse printing options, including direct-to-garment, sublimation, embroidery, and cut-and-sew techniques.
• Flexibility in choosing providers, enabling control over product quality, shipping costs, and production times.

Website: printify.com

3. Gooten

Gooten offers a catalog of over 280 customizable products, ranging from apparel and wall art to premium home décor, drinkware, and accessories. With a fulfillment network of more than 50 manufacturers across 70+ global locations, Gooten is equipped to help print-on-demand businesses scale efficiently. Orders are typically produced within 3-4 business days and shipped at flat rates, making logistics straightforward.

Outstanding Features:

• Over 280 customizable products across diverse categories, including premium home décor and accessories.
• Fulfillment network spanning 50+ manufacturers in 70+ global locations for seamless scaling.
• Flat-rate shipping with discounted rates for additional items in the same order.
• A mockup generator to preview products before finalizing designs.
• Shopify Certified App Partner, ensuring high-quality service and performance for Shopify merchants.

Website: gooten.com

4. Apliiq

Apliiq is a Los Angeles-based print-on-demand app specializing in retail-quality private-label apparel. It offers extensive customization options, making it an ideal choice for those looking to start a clothing brand with unique designs. Apliiq emphasizes quality assurance, ensuring that every product meets high standards before shipping.

Outstanding Features:

• Custom woven label options with plans that include 100 sewn-on labels for branding.
• Quality assurance through in-house production artist review before fulfillment.
• Weight-based shipping with free shipping for US bulk orders over $100 and international shipping to over 150 countries.
• Rush order fulfillment is available for a 10% fee, alongside expedited shipping options.
• Specializes in retail-quality private-label apparel to elevate brand appeal.

Website: apliiq.com

5. Gelato

Gelato is a global print-on-demand platform that partners with over 100 print providers to fulfill orders in more than 200 countries. It uses an algorithm to automatically select the most suitable print provider based on delivery location, enabling fast fulfillment with 72-hour delivery for some products. Focused initially on custom paper products, Gelato now offers apparel, wall art, and stationery for customization.

Outstanding Features:

• Global fulfillment network with over 100 print partners across 200+ countries.
• Algorithm-driven provider selection for optimized delivery locations and times.
• Fast 72-hour delivery for specific orders.
• Ability to print on various areas of apparel, including the front, back, and sleeves.

Website: gelato.com

6. SPOD

SPOD, owned by Spreadshirt, is known for its speedy fulfillment times, with 95% of orders shipped within 48 hours. While its selection of white-label products is smaller compared to other print-on-demand platforms, SPOD stands out with competitive pricing and a straightforward shipping model based on total order value. It is ideal for merchants who want to set up custom shipping rules for upselling and cross-selling.

Outstanding Features:

• Fast fulfillment, with 95% of orders shipped within 48 hours.
• Competitive pricing and a shipping model based on total order value.
• Domestic shipping starts at $3.65, with an estimated delivery of 3-8 business days.
• Multiple printing options, including digital direct, thermal sublimation, digital transfer/laser transfer, and unique flex.
• Simple and effective shipping rules for upselling and cross-selling.

Website: go.spod.com

7. Teelaunch 

Teelaunch is a print-on-demand platform that caters to apparel and luxury brands, offering a competitively priced catalog that includes unique items like Bluetooth speakers. Known for its professional mockup tool, Teelaunch helps merchants create marketing materials with high-quality product images, including lifestyle photos for certain products. Production typically takes 3-6 business days, with shipping available from the US, Canada, or the UK.

Outstanding Features:

• Unique product offerings, including items like Bluetooth speakers, tumblers, and cooking boards.
• Professional mockup tool that generates high-quality product images, including lifestyle photos.
• Customization options allow customers to personalize products by adding names or uploading photos.

Website: teelaunch.com

Challenges of Selling Print-on-Demand Hats

Selling print-on-demand (POD) hats comes with its own set of challenges for which every merchant should be prepared. Here are some key obstacles to consider:

• Ensuring High-Quality Products and Designs: Sellers must invest time in researching market trends and competitors’ designs to ensure their hats stand out in both quality and uniqueness. Poor-quality designs or materials can also damage your brand’s reputation, making it essential to adhere to print/embroidery guidelines and avoid the temptation to replicate others' intellectual property.
• Choosing the Right POD Supplier: A reliable print-on-demand hat supplier is essential to ensure timely delivery and high-quality products. Delays in production or subpar quality can lead to cart abandonment and lost sales. 
• Managing Customer Expectations: As 73% of consumers are willing to pay more for high-quality products, providing premium products and fast delivery can help establish trust and loyalty.
• Building a Professional Storefront: A professional and user-friendly online store is critical for encouraging purchases. Neglecting factors like SEO, low-quality product images, and a complicated checkout process can create friction that deters potential buyers. 
• Marketing and Sales Strategy: Effective marketing strategies are essential to growing your POD hat business. Social media and influencer marketing can boost brand awareness and drive traffic to your store. 

Frequently Asked Questions

1. What are cooling hats?

Cooling hats are stylish and practical accessories designed to help keep you cool in hot weather. They use moisture-wicking fabrics and advanced technology to draw sweat away from the skin, providing comfort and relief from the heat while you're outdoors.

2. Why are cooling hats popular?

Cooling hats are popular because they offer both style and comfort. They allow individuals to make a fashion statement while also providing protection from the sun, keeping them safe and comfortable in hot weather.

3. Is print-on-demand profitable?

Yes, print-on-demand can be profitable. While the profit margins may be lower compared to bulk purchases, you can still price your products strategically to ensure a profit. With careful planning and cost management, print-on-demand can be a successful business model.

4. How do you price print-on-demand products?

To price print-on-demand products, follow these steps:

• Assess the total product cost, including design, production, shipping, taxes, and platform fees.
• Add a profit margin to the product cost to determine the retail price.
• Account for other expenses like marketing and advertising.
• Calculate minimum orders by dividing monthly costs by the profit margin.
• Set a price that covers all expenses and still provides a profit margin.

Ready To Start POD Hats Business?

Selling print-on-demand hats is an exciting and profitable way to turn creativity into income. By following the steps outlined in this blog—choosing the right platform, targeting your audience, designing compelling products, partnering with reliable suppliers, and streamlining order fulfillment—you can build a successful and sustainable hat business. The key to standing out in this competitive market is a strong brand, high-quality designs, and exceptional customer service. So, get creative, stay focused, and watch your ideas come to life—one stylish hat at a time. 

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