The Ultimate Guide to Custom Cowboy Hats and Trucker Hat Bars
By: Melody Posted on: May 23, 2025Discover why trucker hat bars are trending in America now. This comprehensive guide explores everything from hat styles and customization techniques to setting up profitable hat bars and sourcing the right blank hats. Learn how to capitalize on the booming personalized hat trend in the form of Hat Bars, with CapBargain's high-quality blank hats from OTTO CAP.
Who thought the popularity of personalized hats across the United States would give rise to another trend? It’s all the rage now. Custom trucker hats, custom cowboy hats, and a whole new definition for custom hat experiences. And with excellent profit potential.
We are talking about hat bars. Those specialty stalls or pop-ups where you make your own trucker hat, baseball cap, or even a custom cowboy hat.
CapBargain has been observing this trend for a while now, and it seems to be steadily growing beyond a niche. More shops, event planners, and entrepreneurs are starting to invest in hat bars or pop-ups that offer blank hats visitors can personalize on the go. Trucker hat patch hubs, custom hat bars at bridal bashes and birthday parties - everyone wants in on the trend. And at the top of it all lies good quality blank hats that people would want to customize.
This guide breaks down everything you need to know about hat bars, customization options, and how to choose the perfect wholesale hats for your next project.
Hat Types & Customization
Custom Cowboy Hats vs. Custom Trucker Hats
In Nashville, it’s custom cowboy hats and custom trucker hats that are getting most of the attention. In Austin, felt and straw cowboy hats remain popular, but trucker caps and snapbacks appear to be more commonly worn now. These types of hats serve different market segments, basically, but share popularity in the customization space.
Custom cowboy hats typically feature felt or straw construction with wide brims and tall crowns. Their relatively higher price point still doesn't deter customers who want to personalize statement pieces for special occasions. Branded cowboy hats make excellent high-dollar offerings at upscale events and luxury boutiques.
Trucker hats, on the other han,d have always been popular in the custom hats domain. The demand further went up after multi-patch trucker hats went viral. Foam front trucker hats are top picks for patch customization owing to the smooth placement surfaces. CapBargain's wholesale selection focuses primarily on high-quality blank trucker hats, giving decorators the perfect options to showcase at hat bars and customize in a myriad of ways.
Popular Hat Styles
Trucker hat bars generally go for 5-panel trucker hats. The classic profile of these hats, a slightly curved brim, and the front canvas make it a great option for larger front patches. The hats can offer a vintage look or a modern on,e depending on the customization, which makes it a popular pick for casual hat bars and multi-patch decorations. The OTTO CAP 39-165 Trucker Cap is basically gold standard in this category, and one of the top picks of our customers that want to set up a trucker hat bar.
For hat bars that want to bring a little more diversity to their trucker hats lineup, stocking blank 6-panel trucker hats is not a bad investment. Despite the seam that goes through the front panel, the hats’ construction gives more surface area for patch placement and embroidery. These hats also tend to fit more head shapes comfortably. Styles like the OTTO CAP 112-3 Mid Profile Trucker or the OTTO CAP 83-3 Low Profile Trucker are superb choices to offer as blanks for visitors of the hat bar to customize.
Personalization Options
There are small-scale hat bars that offer only printing or basic embroidery as customization options. But with more hat bars popping out, multiple decoration options will have to be on the catalog.
Patches: Pre-made or custom embroidered patches can be heat-pressed or sewn onto hats
Embroidery: Direct stitching for logos, names, or designs
Laser Branding: Creates burned-in designs on leather patches or hat parts
Distressing: Gives hats a worn, vintage appearance through fraying or fading
Hat bars can offer customization methods depending on their equipment, budget, customizability of the styles they offer, and customer expectations. The idea is to offer visitors a nice inventory to choose a blank hat from, and customize it the way they want for the occasion.
Hat Bars & Experiences
What exactly is a Hat Bar and what makes a Trucker Hat Bar different?
A hat bar is an interactive merchandise experience where customers select and customize their own headwear. Instead of offering customized hats to visitors, you offer blank hats. Visitors will choose the kind of hat they want, and then have it customized on-the-spot by choosing a customization method and maybe even the custom elements. Customers start with a blank hat then choose from various patches, designs, and placement options. The hat gets customized on-site, creating an engaging retail experience.
A trucker hat bar specifically focuses on personalizing blank trucker caps with patches, embroidery, or other decorations.
The concept works similarly to DIY food stations but for headwear.
Trucker Hats: Foam Front vs. Cotton Panels - Foam front trucker hats feature a polyester foam panel on the front section, creating a firm, smooth surface ideal for patches. The rigid structure allows patches to lie flat without wrinkling. Foam front styles that are durable are a solid investment for hat bars specializing in patch customization.
Cotton panel trucker hats offer a softer look and feel. While they accept embroidery well, they may present challenges for patch application, often requiring additional backing or adhesive. These hats work better for direct embroidery applications than patch-focused customization. Still, CapBargain has been doing patch customizations on cotton as well as cotton-poly blend trucker hats. Talk to our Customer Support team if you need help with customization or collaborate with us on embroidery and patch decorations on your hats.
How Hat Bars Work
Hat bars can be a great addition in several settings. They can even go mobile.
- Pop-Up Events: Temporary hat customization stations at concerts, festivals, or trade shows offer attendees a chance to design themselves a custom hat making a memorable souvenir.
- Boutique Add-Ons: Clothing stores can install permanent or weekend-only hat bars to boost foot traffic and increase average purchase value.
- Parties and Celebrations: Hat customization parties have become popular for corporate team-building, bachelor/bachelorette celebrations, and birthday gatherings. These DIY custom hat party setups deliver interactive entertainment.
How to Start a Hat Bar
Launching a hat bar is not sophisticated at all, which explains why the idea is getting a lot of praise.
Anyone can set up a hat bar. But they will need to invest in:
- Quality Blank Hats: Partner with wholesale suppliers like CapBargain to source blank hats of excellent quality.
- Decoration Equipment: Heat press, embroidery machine, or patch application tools
- Design Options: Stock of popular patches, thread colors, or design templates
- Display System: Attractive hat displays and patch selection boards
- Staff Training: Employees skilled in hat customization techniques
Starting costs vary based on equipment choices, area of the bar, and inventory depth. Many successful hat bar operators started with a focused inventory (2-3 hat styles in core colors), and expanded as demand grew.
Here’s a checklist of everything you will need to start a hat bar.
- Heat Press - You can go for low-budget ones to learn but make sure it can also fit child sizes.
- Heat Press Accessories - This includes items you need, like teflon sheets, heat tapes, heat tape dispensers etc.
- Blank Hats - You can source blank hats from wholesale suppliers like CapBargain to minimize your overall spend. At CapBargain, you can get the finest blanks from OTTO CAP - America’s largest source of blank and custom headwear with budget-friendly per-unit and bulk price tags.
- Patches - Customization is never complete if there are no patches. This is particularly important for trucker hat bars as trucker hats with patches are incredibly popular in the United States. Patches can be bought from retailers or Amazon. There is also an option to showcase your own custom patches. Etsy is also an excellent source for premium patches.
- Power - This is important if you plan to have your hat bar open outdoors. A 1000W portable power station is sufficient for beginners.
- Shipping Partner - You can offer shipping too by partnering with a shipping service. This allows you to not disappoint customers with customization orders that cannot be delivered immediately.
- Embroidery Machine & Equipment - If you plan to offer basic embroidery, you can use a cheap machine to begin with and learn the process. You can start with a PE900 that has a 5x7 embroidery field, offering small, unsophisticated hat embroidery.
Best-Selling Hats to Use in Hat Bars
OTTO CAP 39-165 Foam Front Trucker Hat - Consistent bestseller in CapBargain and a top pick for hat bars. We received very positive reviews from a customer running a hat bar in Nashville, and they loved how the hat looks with patches and decorations. Available in dozens of colors and color combinations, this hat serves as the backbone of many successful custom hat operations.
Other popular options include:
OTTO CAP 31-069 Mid Profile 5 Panel Baseball Cap - Another popular pick due to the per-unit pricing and color choices, the 31-069 is great for embroidery and printing. It’s also leading as one of the best hats for patches.
OTTO CAP 83-473 Low/Mid Profile Trucker Cap - Coming with a poly-cotton front panel, this 6-panel trucker hat also comes in over 60 colors which explains why it is a great pick for hat bars. Excellent for patches.
OTTO CAP 112-1 6 Panel Mid Profile Mesh Back Trucker Hat - OTTO CAP’s answer to the iconic Richardson 112, this trucker hat costs less but is every bit as amazing as its counterpart in terms of comfort, construction and breathability. It comes in 93 colors and has consistently delivered excellent results with embroidery and patches.
OTTO SNAP 125-1038 6-Panel Snapback Hat - Designed to appeal to the youth and headwear enthusiasts that prefer hats with modern designs, the 125-1038 features a durable snap closure and a cotton fabric construction. Comes in 19 colors curated to deliver the modern appeal.
OTTO FLEX 11-1172 Low Profile Fitted Cap - Designed to adapt to any head shape and deliver maximum comfort, the 11-1172 is part of OTTO CAP’s OTTO FLEX lineup and is a performance cap. In addition to comfort, the cap is moisture-wicking and anti-bacterial.
OTTO CAP 135-1 COMFY FIT 6 Panel Low Profile Trucker Hat - Part of the OTTO COMFY FIT lineup, the 135-1 trucker hat is designed specifically for superior comfort and customizability. Though the color options are limited, the cap certainly delivers value and is among the best in comfort, in the price segment.
OTTO CAP 18-1322 6-Panel Low Profile Style Dad Hat - Made of 100% washed cotton, the unstructured 18-1322 comes with a classic dad hat look. Great pick if you want to offer blank hats with a vintage appeal.
Best Materials for Hat Customization
The success of hat customization lies heavily on the right base materials. For trucker hat bars, polyester foam fronts provide the best foundation for patches and heat-applied designs. Cotton panels accept embroidery well but may not hold patches as securely.
Custom hat makers USA-wide recommend different materials based on the decoration method:
- Heat-applied patches: Polyester foam front panels
- Direct embroidery: Cotton twill or polyester blends
- Leather patches: Any sturdy hat material
Cowboy Hat Materials and Branding
Branded cowboy hat options typically come in felt or straw variations:
Felt Cowboy Hats: Made from wool or fur blends, these hats accept branding through leather patches, hat bands, or pinned emblems. Their sturdy construction holds up well to decoration but typically requires specialized equipment.
Straw Cowboy Hats: Lightweight and popular for warm weather, straw hats can be customized with branded hat bands, patches at the front or side, or subtle embossing. The material limits some customization options but creates distinctive looks. CapBargain offers a curated selection of blank straw hats that you can easily turn into custom-branded cowboy hats with patches or embossing.
Ideal Patch Types for Custom Hats
The best hats for patches pair with specific patch types:
- Embroidered Patches: The most common option, featuring thread-based designs on fabric backing with heat-activated adhesive. These work excellently on foam front trucker hats.
- Leather Patches: Natural or synthetic leather pieces with debossed, branded, or printed designs. These add premium appeal to both trucker and cowboy styles.
- Sublimated Patches: Printed designs transferred to white polyester patches. These allow for photographic designs and gradients impossible with other methods.
- PVC Patches: Rubber-like dimensional patches that add texture and durability. These work well for outdoor brands and rugged aesthetics but is not very common across hat bars.
For multi-patch trucker hats, combining complementary patch types creates a more dynamic aesthetic. After the style went viral, many hat bars now give visitors the option to create their own custom trucker hat by mixing a variety of patch styles across the hat's surface.
How Resellers Profit with Custom Hats
Resellers can generate significant margins through custom hat sales:
- Volume Discounts: Purchasing blank hats wholesale through CapBargain significantly reduces per-unit costs
- Value-Add Pricing: Basic customization can increase perceived value by 3-5x the blank hat cost
- Upselling Opportunities: Multiple patches or premium decoration techniques increase average order value
- Recurring Revenue: Event series, team sports, and corporate clients create ongoing custom hat orders
Many successful hat bar operators report profit margins exceeding 70% on custom pieces, making this category particularly attractive for retail and event businesses.
Maximizing Hat Bar Business Profits
- Core Inventory Focus: Stock depth in proven sellers like the OTTO CAP 39-165. Offering too many styles can often confuse visitors, and they will likely end up not ordering anything due to the complexity.
- Color Coordination: Select hat color combinations that work with your most popular patches.
- Quantity Breaks: Work with suppliers like CapBargain to minimize your investment and subsequently boost profit margins.
- Seasonal Planning: Pre-order seasonal colors 2-3 months ahead to avoid stock shortages
Our Recommendation: For new businesses, starting with 2-3 hat styles in 4-6 color combinations provides sufficient variety without overextending inventory investment.
Hat Bars for Events
Event planners increasingly include trucker hats for events in their service offerings. Custom hat experiences work exceptionally well for:
- Corporate Events: Company-branded hats with employee-selected patches create team-building moments and practical takeaways.
- Weddings: Bachelor/bachelorette parties and wedding weekends increasingly feature custom hat stations. Guests choose patches reflecting the couple's interests, event location, or inside jokes.
- Festivals and Conventions: Pop-up trucker hat bars provide excellent revenue streams at larger gatherings. Attendees consistently show a willingness to purchase customized memorabilia that they help design.
The interactive nature of hat customization creates memorable experiences while generating substantial profit potential for event businesses.
Conclusion
The hat bar concept continues gaining momentum across retail, event, and promotional markets, especially trucker hat bars. With the right wholesale hat supplier like CapBargain, businesses can offer compelling custom hat experiences without excessive inventory investment. The personalized hat trend shows no signs of slowing down, making now the perfect time to explore this profitable market segment.
Frequently Asked Questions
What is a hat bar event?
Basically, any event that justifies the presence of a hat bar can be called a hat bar event. Or it could be exclusively for hat bars that offer specialty customization services and curated hat selections.
Where can I buy hats for a hat bar or hat customization party?
CapBargain has customers that used to buy blank hats from Amazon in low volumes. But we recommend sourcing blank hats in bulk from a wholesale hats supplier like us. This way, you can get blanks at wholesale prices that will be lower compared to Amazon listings. At CapBargain, we offer a wide range of hats for hat bars and customization from OTTO CAP at guaranteed best per-unit and bulk prices. Additionally, you also get free shipping on orders above $119. No account or membership needed either.
What is the best trucker hat for applying multiple patches?
From the feedback we gathered from our customers that specialize in hat customizations, the OTTO CAP 39-165 trucker cap is by far the absolute best. It’s a signature style from OTTO CAP, and one of the top selling wholesale hats in the United States. The 39-165 was at the top of the multi-patch trucker hat trend. Still is.
How does a trucker hat patch bar work at parties?
You can have a hat bar open at a corner of the venue for people to create their own personalized hats. This could be part of an event or a celebration. Your selection, colors, and customization options are the selling points. Trucker hats typically price personalized trucker hats with patches between $35 and $70.
How does custom hat-making experiences work at hat bars?
With a hat bar service, you are offering your customers an environment that delivers an interactive experience to guests. The hat bar can be tailored for the event or occasion. Each guest visiting the hat bar will select a hat style and material first. Then they work with the in-house designers to personalize the blank hat of choice with accessories and details in any way they want. The visitor can take it home as a souvenir or a keepsake of the event.
What kind of accessories can be offered at hat bars for customizing hats?
Any kind if they go well on hats as decoration elements. You can use patches, pins, ribbons, chains, suede, even poker chips, and feathers.
What is a mobile hat bar?
As the name suggests, a mobile hat bar can go wherever clients want. It can go directly to events, celebrations, and gatherings to offer guests the “make your own hat” experience. A mobile hat bar charges a fee for their service, which typically also covers travel expenses.
Is a hat bar the same as a hat store?
No. Hat stores typically offer blank or customized hats at a price. Hat bars offer blank hats that guests can choose based on their preference, and then customize on the spot by working with the hat bar’s designers. Customizations, except for complex designs, are mostly done promptly at the hat bar so guests can take their orders home. Additionally, hat bars can also be offered as a service to engage and entertain guests at an event, celebration, or gathering.
What type of hats should a hat bar carry?
That is entirely your preference. You can carry any blank style of hats that can be customized on the go. Trucker hat bars primarily offer blank trucker hats and customization services. It does not mean they can’t offer any other type of hats. Hat bars currently offer everything from baseball hats and trucker caps to dad hats, cowboy hats, and fedora.
How can a wholesale hats supplier like CapBargain help set up hat bars?
By taking the inventory dilemma out of your equation, mainly. Then by delivering value by minimizing your investment. CapBargain offers you a large selection of blank hats for you to display at your hat bar - including trucker hats, baseball caps, dad hats, beanies, performance hats, camo hats, and more. With our market-best pricing on every single style in our inventory, you get maximum value on your orders. Even more on bulk orders. Blank orders above $119 also save you shipping costs. Sourcing blank hats in bulk from CapBargain significantly reduces your investment in stocking. Additionally, you can also collaborate with our in-house Customization Team to customize large order volumes or complex design orders.