Wholesale Hat Trends 2025: CapBargain's Top Styles & Success Stories
By: Melody Posted on: Apr 2, 2025We're Only Getting Started!
The wholesale hats market in the United States continues to grow, and thanks to our customers and their faith in us, we are growing, too.
This is CapBargain, wrapping up a wonderful first quarter of 2025 as winter recedes. Time flies when you get busy supplying blank and custom hats to people with amazing ideas.
Our warehouses have been buzzing with activity these past few months as custom orders for wholesale baseball hats poured in. We’ve been busy managing all the orders and getting them shipped fast to a wide range of customers - from small boutique owners to medium and large-sized organizations with amazing ideas for spring promotions with hats. We’re glad that they chose headwear from OTTO CAP and that they chose to get their items from us.
We noticed more retailers among our customers in January, likely refreshing their inventories after the holiday rush. Many of them also had pretty epic ideas for Valentine’s Day customizations (which involved a lot of red trucker hats with heart designs and patches). We took a hit in February as many of the popular styles went out of stock, and inventory updates were scrambled. Though we managed to process most orders, a few blank orders had to be taken back and refunded. Still, we were given another chance by a lot of patient customers.
Thanking them all for the trust and for recognizing our efforts. Let’s move on to our hottest sellers from 2024 through March 2025.
CapBargain Bestsellers
In 2024, our wholesale snapback hat inventory went dry more times than ever. Orders, both blank and custom, of snapback hats went up considerably. These styles with snap closures sold the most (not in any particular order).
OTTO SNAP 125-978 6 Panel Mid Profile Snapback Hat
OTTO CAP 39-165 Foam Front Trucker Hat
OTTO CAP 32-467 5 Panel Mid Profile Trucker Hat
OTTO CAP 32-285 5-Panel Mid Profile Trucker Hat
OTTO CAP 83-1239 6 Panel Low Profile Trucker Hat
The top 5, as you can see, were trucker hats, mostly from our wholesale 5-panel hat collection. From the feedback we gathered from our customers (retailers mostly), it seems consumers can’t get enough of trucker hats - ones with snap closures, fitted trucker hats, and Flexfit trucker hats, and pretty much every variety was well received.
But we saw a slight increase in other types of hat styles too. The 31-069 baseball cap—a customer favorite (and also one of our top sellers overall in both 2024 & 2025)—now gets more custom orders. The 11-1172 Flexfit cap got the recognition it deserves, with more of our customers finding it to be exceptionally good. We've had to reorder the 39-165 and 31-069 from OTTO CAP twice already this year.
It’s been an absolute joy. But the best thing about all of this is seeing what our customers create with the blank hats.
Best Customizations We’ve Seen Since 2024
There were a lot of standout custom designs from the past year that made our jaws drop. Though we unfortunately can’t show everything from that big list, it still gives us great pleasure to show a few that were just brilliant.
1. The Charm of Missouri
A beautifully crafted custom trucker hat by Whitney Savolt from Outlaw Hat Bar Co., inspired by the beauty of Missouri.
2. The Coors, Golden Colorado
Another amazing design by Whitney Savolt from Outlaw Hat Bar. We were blown away by the detail.
3. A bunch of designs by CodeofOutlaw by Christine
Just what happens when you give trucker hats to a super creative blue-collar wife. These designs make the hats bold statement pieces. Just looking at them tells you how synchronized the details are to deliver that vibe CodeofOutlaw got a reputation for.
We are thinking about opening a different line to showcase our customers’ creative flair. Tag us on social media or shoot us an email with photos of your custom creations.
Fresh Styles on the Block
We always tried to stay ahead of headwear trends. With hats from OTTO CAP, this has been quite easy, honestly. We have added a few new styles to our catalog this quarter, and these fresh additions bring a lot more flair to our inventory. There are 18 new styles. But we recommend checking these out first.
OTTO CAP 14-2 Boonie Hat
A lot of customers wanted boonie hats last year. The 14-2 is our first response. Comes in 7 colors, features a performance sweatband with moisture-wicking, and is available in M (7 1/8) and L (7 1/2) sizes. A well-fitting, comfy hat at an excellent price point.
OTTO CAP 3932-1 5 Panel High Crown Foam Front Trucker Hat
Inspired by OTTO CAP’s iconic 39-165, the 3932-1 is more compact and comes with that foam front panel our customers love to customize. The matching color braid and 8 rows of stitching on the visor stand out.
OTTO CAP 9505-3 5 Panel Snapback Foldable Hat
Built to be a handy companion in travels, the 9505-3 allows effortless compaction. The rather big front panel offers ample space for vibrant customizations. It’s unstructured but still holds its shape well and is foldable.
How We've Improved
2024 was also the year that helped us identify a few shortcomings in packing and shipping. So we gathered a lot of feedback from our customers along with quite a lot of suggestions to make some improvements. And we did.
- Streamlined our shipping—we added more resources to handle shipping and returns. Now it will be faster with no more unpleasant surprises on order items and quantity.
- Bulk discount adjustments - To stay competitive, we optimized our tiered pricing, particularly on our bestselling styles and a few promising ones. You get even more savings on larger orders than before.
- Optimized Custom Design Creator - The free Custom Design Creator tool on our website is our team’s finest work. We have made some adjustments in the tool to make it perform even better without bugging out at any point. The tool has also been readied to accommodate more customization options we are planning for 2025.
- Customer Support Expansion—We've doubled our support team to handle and resolve queries and grievances promptly.
What's Under Our Hat for the Rest of 2025?
While we can't reveal all our secrets just yet, we're cooking up some exciting stuff for the coming months.
- Adding more styles for outdoor adventurers and a few more from OTTO CAP’s OTTO FLEX, OTTO COMFY FIT, and OTTO SNAP lineups.
- A plan to give more exposure to our customers’ outstanding customization ideas.
- Sales offers that guarantee even more value to all customers who have relentlessly given us their support
- Enhanced custom embroidery capabilities and new customization options
Got questions? Need recommendations? Just want to chat about hats? (We love that!) Reach out to your dedicated Customer Service Executive or hit up our customer service hotline.
Here's to making the rest of 2025 even more captivating than it's already been!
Frequently Asked Questions
What style of trucker hat is most popular?
The OTTO 39-165 is a top-rated wholesale trucker hat, known for its structured five-panel build and polyester-nylon fabric blend. It's especially popular for multi-patch designs at custom trucker hat bars. With smooth surfaces ideal for embroidery or heat transfer, this cap is a favorite for custom apparel, brand merch, and uniform programs, consistently ranking in high-intent trucker hat searches.