Bucket Hat Co.: Bulk Custom Bucket Hats, Dad Hats and 5-Panels
Bucket Hat Co. is a brand of Battle Born Clothing in Yerington, Nevada. We embroider and leather-patch Decky bucket hats, YP Classics dad hats and five-panel caps in-house, from 12 pieces to pallet runs, and ship nationwide.
- No hard minimum
- 28-day turnaround
- Ships nationwide
- Patches since 2020
Bucket Hat Co. makes one thing: custom bucket hats, dad hats and five-panel caps with your logo on them. Battle Born Clothing has made leather patches since 2020 on an 80-watt CO2 laser and runs two commercial embroidery heads in-house. We are an authorized decorator for Carhartt, Nike and OGIO, we redo our own errors for free, and standard turnaround is 28 days from proof approval. Decoration is $7.00 per hat at 24, $6.50 at 48 and $5.00 at 144 for embroidery or a laser-engraved leather patch; the blank is quoted per job, usually the same business day. Send artwork, a quantity and a style and you will have a number.
Bucket hats, dad hats and 5-panels we decorate
Decky 961 Relaxed Polo Bucket Hat
Our lead bucket hat: soft polo-twill crown, stitched brim, fitted sizes. Embroidery or leather patch.
Blank quoted per job; embroidery from $5.00 per hat at 144
Details →
Decky 450 Structured Cotton Fisherman's Hat
A firmer bucket with a structured crown and a flatter brim. Sits square; good for larger logos.
Blank quoted per job; embroidery from $5.00 per hat at 144
Details →
Decky 980 Relaxed Terry Bucket Hat
Terry-cloth bucket for pool, beach and retro brand drops. Sewn leather patch or embroidery.
Blank quoted per job; embroidery from $5.00 per hat at 144
Details →
Decky 5301 Relaxed Ripstop Bucket Hat (camo)
Ripstop bucket in camo patterns. The custom camo hat for hunting, fishing and outdoor brands.
Blank quoted per job; embroidery from $5.00 per hat at 144
Details →
Decky 5303 Ripstop Boonie Hat
Wide-brim boonie in ripstop and camo. Full sun coverage for guides, crews and range staff.
Blank quoted per job; embroidery from $5.00 per hat at 144
Details →
YP Classics 6245CM Unstructured Dad Hat
The standard custom dad hat: low-profile unstructured cotton twill, curved bill, strap closure.
Blank quoted per job; embroidery from $5.00 per hat at 144
Details →Bulk bucket hat orders for events, camps and resorts (144 to 1,000+)
Large runs are where bucket hats get cheap to decorate. At 144 pieces embroidery or a leather patch is $5.00 per hat and holds there as the quantity climbs. We schedule the run across both embroidery heads or the laser and the hat press so the whole order ships together.
What a 250-hat order looks like
250 Decky 961 relaxed polo buckets, one embroidered front logo: 250 x $5.00 = $1,250.00 decoration plus $18.99 digitizing, plus the quoted blank per hat. Split across colors with the same logo and the price does not change. Fitted sizes (S/M and L/XL) count as one quantity.
Mixing buckets, dad hats and 5-panels
Mix styles freely: buckets for the crew, dad hats for the office, patch five-panels for sponsors. With identical decoration the total quantity sets the tier. Each style gets its own blank price line on the quote.
Reorders
We keep your digitized file and patch art. Reorders skip digitizing and go straight to proof. Battle Born Clothing does not run team or company online stores; we do straightforward bulk orders with one invoice.
Leather patch five-panels and dad hats for brands and breweries
A laser-engraved leather patch on a YP 6502 or Richardson 112FP five-panel is the hat breweries, outfitters and retail brands sell at the counter. We cut and engrave the patch in-house and glue it with a heat process on a two-platen hat press, or sew it on for $1 more. No setup fee, no minimum.
Patch sizes and shapes
Rectangles, rounded rectangles, circles and custom outlines, usually 2.5 to 3 inches wide. Natural tan, brown, dark brown and black leather. The proof shows the patch at true size on your hat.
Patch on a bucket hat
Yes, on cotton buckets like the Decky 961 and 450. On terry and ripstop we sew it. More on the leather patch page.
Custom camo hats
Decky 5301 ripstop camo buckets, Decky 5303 camo boonies, Richardson 112PFP printed camo five-panels and Decky 6304 Multicam five-panels. A leather patch separates the logo from the pattern; single-color embroidery works for simple marks.
Who orders camo
Hunting and fishing guides, ranches, shooting ranges, outdoor retail brands and crews that work outside. See the fishing and outdoor page.
Small runs: 12 to 47 hats
No hard minimum. A dozen dad hats for a startup or 24 buckets for a bachelorette weekend is $8.00 or $7.00 per hat to decorate plus the blank. Same proof, same 28-day turnaround, same machines as the big orders.
Why order custom bucket hats from us
- Leather patches made in-house since 2020 on an OMTech 80-watt CO2 laser; no setup fee.
- Two commercial single-head embroidery machines (Happy HCD2-1501 and YunFu 15-needle) with Rapos thread and Maggie magnetic frames.
- Decky bought direct, plus SanMar (Reno) and S&S Activewear, so hard-to-find bucket hat colors are reachable.
- No hard minimum; price breaks every 24 pieces down to $5.00 decoration at 144.
- Digital proof at true size before production, and a free redo on our own errors.
- Standard 28-day turnaround from proof approval; rush quoted per job.
- Authorized decorator for Carhartt, Nike and OGIO.
- Quotes usually the same business day. Ships nationwide from Yerington, Nevada.
How much do custom bucket hats cost?
All-in means blank plus decoration per hat. On this site the decoration is fixed by quantity and the blank is quoted per job, usually the same business day. The table is for our lead style, the Decky 961 relaxed polo bucket hat, with a front logo under 6,000 stitches or a laser-engraved leather patch. Battle Born Clothing prices break every 24 pieces. Same logo, same order: every style counts toward the same price break.
| Quantity | Blank (961) | Embroidery | Leather patch | All-in each |
|---|---|---|---|---|
| 12-23 | Quoted per job | $8.00 | $8.00 | Blank + $8.00 (emb) or + $8.00 (patch) |
| 24-47 | Quoted per job | $7.00 | $7.50 | Blank + $7.00 (emb) or + $7.50 (patch) |
| 48-71 | Quoted per job | $6.50 | $7.00 | Blank + $6.50 (emb) or + $7.00 (patch) |
| 72-95 | Quoted per job | $6.50 | $6.50 | Blank + $6.50 (emb) or + $6.50 (patch) |
| 96-119 | Quoted per job | $6.00 | $6.00 | Blank + $6.00 (emb) or + $6.00 (patch) |
| 120-143 | Quoted per job | $6.00 | $5.50 | Blank + $6.00 (emb) or + $5.50 (patch) |
| 144+ | Quoted per job | $5.00 | $5.00 | Blank + $5.00 (emb) or + $5.00 (patch) |
How long does a custom hat order take?
28 days from proof approval for standard orders. Count back from your event, add a week for shipping, and send the quote request about six weeks out. Rush is quoted per job.
Who orders bucket hats and dad hats from us
Events and festivals
Staff, volunteer and sponsor bucket hats in the hundreds, usually against a hard date.
Read more →Fishing and outdoor brands
Camo buckets, boonies and patch five-panels for guides, outfitters and outdoor retail.
Read more →Retail and streetwear brands
Private-label dad hats, terry buckets and 5-panels decorated to order, 24 to 500 pieces.
Read more →Schools, camps and youth programs
Sun hats and camp caps for students, counselors and teams, in fitted sizes where it matters.
Read more →Breweries and taprooms
Patch five-panels and buckets that sell at the taproom counter, 48 to 144 at a time.
Read more →Resorts, pools and hospitality
Terry and polo buckets for pool, beach and tour staff, plus retail-shop hats for guests.
Read more →Frequently asked questions
What is the minimum order for custom bucket hats?
There is no hard minimum on embroidery or leather patch. Pricing starts at the 12-23 tier and breaks every 24 pieces, with the best decoration price at 144 and up.
How much does a custom bucket hat cost?
Decoration is $8.00 per hat at 12-23 down to $5.00 at 144+, for embroidery or a leather patch. The blank is quoted per job, usually the same business day. See the pricing page for the full tables.
Why is the blank price quoted per job?
Bucket, dad and 5-panel blank prices move with the maker, the color and the warehouse. We quote the live number rather than list a stale one. Our rule is supplier cost times two under $10, or cost plus 35 percent at $10 and up.
How long does an order take?
Standard turnaround is 28 days from the day you approve the digital proof. Rush is quoted per job.
Do you do leather patches on bucket hats?
Yes. Glued on cotton buckets like the Decky 961 and 450; sewn (+$1 per hat) on terry and ripstop. Patches are laser-engraved in-house on an 80-watt CO2 laser.
Embroidery or leather patch: which is better on a dad hat?
Both work. Small embroidery is the classic dad-hat look. A patch avoids stitch pull on the soft crown and has no digitizing fee. The price is within fifty cents per hat either way.
Can you embroider an unstructured hat without puckering?
Yes. We hoop soft crowns on a cap frame with a cutaway backing and keep fills light. The proof flags artwork that is too dense.
Is there a setup fee?
Embroidery digitizing is $18.99 one time per design. Leather patches have no setup fee. Reorders of a saved design have no setup fee.
What artwork do you need?
Vector (AI, EPS, PDF, SVG) is best. A 300 dpi PNG works for embroidery. Leather patches need solid black-and-white art; no gradients.
Do I get a proof?
Yes, a digital proof showing the logo or patch at true size on the chosen hat and color. Nothing is produced until you approve it.
Get a bucket hat quote
Tell us what you need and we'll price it from real blank costs and our decoration matrix. Quotes usually go out the same business day.