Our baseball and trucker caps come in one adjustable size, beanies in one stretch size, and bucket hats in two sizes, S/M and L/XL. For most brands that keeps a cap order simple: one size to stock, with the closure at the back doing the fitting.
This post explains cap sizes fitted vs adjustable, why we build our caps as adjustable, and how to split a bucket hat order between its two sizes.
Fitted and adjustable caps: the difference
A fitted cap is closed all the way round. It comes in a run of head sizes, and the buyer has to pick the right one. A shop selling fitted caps needs stock in every size, and a size that sells out leaves a gap on the shelf.
An adjustable cap has an opening at the back with a closure. One cap fits a wide range of heads, and the wearer sets it in a few seconds.
| Point | Fitted cap | Adjustable cap |
|---|---|---|
| Sizes to stock | Several head sizes | One size |
| Fit | Closed, exact if the size is right | Set by the wearer |
| Ordering | Quantity split across sizes | Full quantity in one size |
| Gifting and merchandise | Risky, size unknown | Easy, fits most adults |
| Online returns | Size is a common reason | Fewer size questions |
Our baseball caps and trucker caps are made as one size, adjustable. If you need a closed-back fitted cap for a specific project, tell us at enquiry. Anything outside our listed styles is private label work, which we consider case by case and confirm at quotation.
Closures for adjustable caps
The closure is part of the look and affects how the cap feels to put on. The main choices are:
- Strap and buckle: a fabric strap through a metal or plastic buckle. It looks finished and suits cotton twill caps.
- Snap back: a plastic strap with press studs. Quick to adjust and common on trucker caps.
Tell us which closure you want for each style. We confirm it on the sample so you can try it before bulk production.
Bucket hats: two sizes, mixed in one style
Bucket hats have no back opening, so they cannot adjust. We make them in two head sizes, S/M and L/XL, and both sizes can sit within the same style order.
How you split them depends on who buys from you:
- Mixed adult audience: split S/M and L/XL fairly evenly, then adjust on reorder based on what sold.
- Younger or women-led audience: weight the order towards S/M.
- Menswear or outdoor audience: weight the order towards L/XL.
There is no fixed ratio that works for every brand. The safest approach is to start balanced, track sales by size, and change the split on the next order. Your first order is the most useful guide you will have, so record sales by size from the day you launch.
The minimum is 300 pieces per style, and the size split and colour split are confirmed at quotation.
Beanies: one stretch size
Our beanies are knitted from acrylic and stretch to fit, so they come in one size. The fit is set by the knit and the cuff depth. A deeper cuff sits more snugly and gives a natural place for a woven fold-over label or embroidery.
If you sell to a younger audience and want a smaller beanie, raise it at enquiry and we confirm what is possible. The same applies to a shallower or deeper fit: the knit and cuff can change how a beanie sits, and we show it on the sample before bulk production.
Sizing details to put in your listings
Even with one size, customers want to know it will fit. Give them clear information:
- Say “one size, adjustable” and name the closure.
- For bucket hats, give the two sizes and a simple note on which to choose.
- For beanies, say “one size, stretch fit”.
- Add a short line on how to adjust the strap or snap.
Measure the sample yourself and use those figures in your listing. If you sell on a marketplace, the seller confirms the current size and listing requirements with that marketplace, and we label and pack to the specification you give us. Our guide to selling caps and hats online covers colours and reorders.
What to send for a quote
To quote your caps accurately, send:
- The style or styles: baseball cap, trucker cap, bucket hat or beanie.
- The fabric: cotton twill or polyester for caps and bucket hats, acrylic knit for beanies.
- Colours, and whether you want two-tone caps.
- The closure, and a structured or soft front.
- For bucket hats, your split between S/M and L/XL.
- Your logo file and where it goes on the cap.
We quote per style, by fabric, quantity and branding. See all four styles and their sizes on our white label caps and hats page, then send your details and we prepare a quotation and a sample cap for you to try.