FAQ’s

Plain (blank) hats from HatsOnline are typically dispatched within 2-3 business days, subject to stock availability. Custom embroidered or printed hats are dispatched within 2 weeks depending on the brand and whether it is a new or repeat order.

New decorated orders (Flexfit, Yupoong, AS Colour, U-Flex): Sample/proof in 4-5 business days, then full production in 1-2 weeks after your approval. Repeat orders: approximately 1-2 weeks.

Legend, Atlantis, Grace Collection: Sample in 3-4 days, full production 2-3 weeks. Repeat orders: approximately 2-3 weeks.

Need it urgently? Contact us on 1300 428 766 — we handle rush orders and will always do our best to meet your deadline.

For plain (blank), digital transferred (DTF) and standard embroidered hats and caps there is no minimum order and the order can be as few as one. For custom embroidered hats with 3D embroidery and badges, the minimum is 10 pieces, which can be a mix of styles, colours and sizes as long as the same logo is applied to all pieces. For screen printing methods, the minimum is 25 pieces.

Minimums exist because 3D Embroidery and badge embroidery requires special skills with lots of set up and internal sampling to ensure a retail quality product. Once your logo is set up, reorders are quick and easy. HatsOnline has supplied custom hats and bulk cap orders to Australian businesses, sports clubs and schools since 2005 and we will help you find the most cost-effective solution for your quantity.

The cost of custom embroidered hats in Australia depends on the hat style, quantity and complexity of your logo. As a guide: 10-24 pieces: typically $25-$40 per embroidered cap 25-47 pieces: typically $20-$32 per cap 48-100 pieces: typically $15-$28 per cap 100+ pieces: contact us for volume pricing.

Plain (blank) caps start from under $10 per unit. Exact pricing for every hat style is shown on product pages at hatsonline.com.au/shop. For a precise quote including your logo and hat style, enquire online and we respond same business day.

Yes, HatsOnline ships custom hats and caps to every state and territory across Australia, including all metropolitan and regional areas. We are based in Brisbane, Queensland, and regularly dispatch orders to customers in Sydney, Melbourne, Perth, Adelaide, Hobart, Darwin and all regional areas nationwide.

Free shipping may be available on qualifying orders. Delivery timeframes vary by destination. See hatsonline.com.au/shipping-delivery or call 1300 428 766 for an estimate.

Yes, plain (blank) hats and caps can be ordered directly online with no minimum quantity. Browse styles from Adidas, Flexfit, Yupoong, AS Colour, Legend, Grace Collection, Atlantis and more at hatsonline.com.au/shop. Filter by style, brand, colour, material or price to find what you need and order instantly.

For bulk blank cap orders over 250 pieces, contact us for a volume pricing quote as significant per-unit discounts apply at higher quantities.

Yes. For plain (blank) hats, physical samples can be arranged before committing to a larger order so you can check the style, fit, fabric and quality in person.

For all custom decorated orders (embroidery or print) over 20 units, providing a sample proof before full production is standard HatsOnline procedure. You will not be asked to proceed to full production without first seeing exactly how your logo looks on the hat. Blank sample fees may apply but are typically credited against your order. A setup fee may apply for new logo artwork on decorated samples.

To arrange a sample, call 1300 428 766 or enquire online at hatsonline.com.au/enquire-online.

HatsOnline stocks over 500 hat and cap styles across 15 categories and 10+ leading brands. If you still cannot find what you need, here are your options:

1. Contact us directly — we may have styles not yet listed online, or can source a specific product from our supplier network.
2. Full custom (indent) order — need a completely unique hat? We manufacture to your exact specifications, minimum 200 pieces.
3. Different decoration method — if the style is right but you need a different branding approach, ask about 2D embroidery, 3D embroidery, screen printing, DTF, laser engraving and woven patches, leather patches, 3D heat transfer.
4. Mixed style orders — embroidery orders can mix styles, colours and sizes with the same logo.

Call 1300 428 766 or enquire online — we will find a solution.

A tracking notification email is sent to you as soon as your order is dispatched from our Brisbane warehouse. This email includes your tracking number and a direct link to monitor your delivery in real time.

If you have not received a tracking email, first check your spam or junk mail folder. You can also log in to your HatsOnline account at hatsonline.com.au/my-account to check your current order status.

If you are still unsure, contact us on 1300 428 766 or email [email protected] with your order number and we will investigate right away.

For best results, logos should be supplied as vector files: .AI (Adobe Illustrator), .EPS or high-resolution .PDF. For print-based decoration, high-resolution .PNG or .TIFF at 300 dpi or above are also suitable. JPEG files can work if the resolution is sufficient.

If your logo is pixelated, low resolution or in the wrong format, do not worry, HatsOnline offers a professional logo redraw service for approximately $50. We will recreate your logo as a production-ready vector file and send you a copy to keep for all future use.

Send us whatever you have via the online enquiry form at hatsonline.com.au/enquire-online and our team will assess it and advise.

We are sorry to hear that. Please contact us as soon as you identify a problem — call 1300 428 766 or email [email protected] with your order number and a photo of the issue if possible.

HatsOnline stands behind the quality of every order. Products that are faulty or do not match your approved proof will be rectified promptly, either replaced or refunded, depending on the circumstances. We aim to respond to all quality issues within one business day.

For our full returns process and policy, see hatsonline.com.au/returns-exchanges.

HatsOnline takes payment security seriously. All transactions on hatsonline.com.au are protected by SSL (Secure Socket Layer) encryption , the padlock icon in your browser confirms this is active.

Credit card details entered at checkout are processed directly by our payment gateway, EWAY (eway.com.au), a leading Australian payment processor. Your full card number is never stored on HatsOnline’s servers and our staff do not have access to it at any time.

For security questions, contact us at [email protected] or call 1300 428 766.

Yes, Order collection is available from our Brisbane location available on website. Please call 1300 428 766 or email [email protected] before arriving to confirm your order is ready and to arrange a suitable collection time.

If you are located in the Brisbane metro area, local drop-off may also be possible, let us know your address when placing your order and we will see what we can arrange.

Payment is required at the time of ordering for all standard orders. HatsOnline accepts the following payment methods:

Credit card: Visa, Mastercard, American Express Debit card
Bank transfer (EFT) — details provided on request

Secure online payment is available directly on the website. For established business customers, payment terms may be available on request — contact us to discuss. For large custom or bulk orders, a deposit may be required before production begins.

The right hat depends on your intended use, industry and branding goals. Here is a quick guide:

Workwear and construction: Wide brim hats with UPF 50+ sun protection for outdoor workers, or structured caps with reflective panels. Browse the UPF Rated range at hatsonline.com.au.

Corporate and promotional: Flexfit or Yupoong structured 6-panel caps for a premium, professional look with embroidered logos. The Flexfit 6277 is our most popular corporate cap.

Sports clubs and teams: Sporty caps, trucker caps or bucket hats in team colours with embroidered or printed logos. We supply clubs across all major Australian football codes.

Schools and childcare: Bucket hats in school colours with UPF ratings are the most practical and popular choice.

Budget promotions and events: Screen-printed caps work well for high-volume giveaways at a lower cost per unit.

Still unsure? Call 1300 428 766 — with 20+ years supplying custom hats and caps across Australia, we will point you to the right style in minutes.