Custom 5-Panel Hats: Seamless-Front Caps With Your Logo or Patch
Short answer: a 5-panel hat has one wide front panel with no center seam, so leather patches and wide logos sit flat. Our most popular are the Zapped Blackhawk ($24.99, water-repellent and vented), the canvas Zapped Patriot ($24.99) and the YP Classics 6006 trucker. Embroidery is about $8 a hat, leather patches $4–$8, and there is no minimum.
5-Panel vs 6-Panel
| 5-Panel | 6-Panel | |
|---|---|---|
| Front | One seamless panel | Two panels with a center seam |
| Best for | Leather and woven patches, wide logos | Classic embroidered logos, 3D puff |
| Look | Outdoor, streetwear, modern | Traditional ball cap and trucker |
| Examples | Zapped Blackhawk, Patriot, YP Classics 6006 | Richardson 112, YP Classics 6606 |
Zapped 5-Panel Hats
| Model | What It Is | Blank |
|---|---|---|
| Blackhawk | 5-panel, medium profile, water-repellent shell with perforated "droplet" vent holes | $24.99 |
| Blackhawk R+ | Blackhawk with a rope across the bill | $24.99 |
| Blackhawk Elite | Perforated spandex/nylon performance version | $32.99 |
| Youth Blackhawk | Youth fit | $24.99 |
| XL Blackhawk | Bigger fit for larger heads | $24.99 |
| Marine | 5-panel front with a mesh back | $24.99 |
| Marine R+ | Marine with a rope across the bill | $24.99 |
| Patriot | 5-panel canvas | $24.99 |
| Patriot R+ | Canvas with a rope across the bill | $24.99 |
| Patriot Waxed | Waxed canvas | $24.99 |
| Commodore | Canvas rope cap | $24.99 |
Other 5-Panel Caps We Decorate
| Model | What It Is |
|---|---|
| YP Classics 6006 | High-crown 5-panel flat-bill trucker |
| DRI DUCK, Richardson and more | Rope and outdoor 5-panels; ask for current styles |
Need the widest front of all? Go to 7-panel hats. Comparing brands? See Zapped Headwear.
How We Decorate It
| Method | Price | Notes |
|---|---|---|
| Flat embroidery | About $8/hat | No minimum; the default for company logos |
| 3D puff embroidery | About $10/hat | Bold, thick letterforms; best on structured fronts |
| Laser-engraved leather patch | $4–$8/hat | Cut and engraved in house, bonded with an industrial adhesive. Sewn on: +$4/hat |
| Side, back or undervisor | Quoted per location | Web address, year, small icon |
| Digitizing | From $16.99 one time | Your stitch file is kept for reorders |
Full rate card on the pricing page. Need a logo first? Our design team can draw or clean it up. AI-generated logos are welcome.
What Customers Say
★★★★★
“Great to work with and awesome availability of products. I was able to get my exact same work shirts that I use but with my logo printed through Battle Born Clothing.”
David Avila · Google★★★★★
“Robert has done a great job getting all our new merchandise logo up and ready for sale. Good guy too. Highly recommend him.”
Mark Johnson · Google★★★★★
“High quality, good prices, great people. Thanks for the great products!”
Anthony F. · Verified PurchaseRead all 45 reviews (4.6 average across Google, Etsy and our store)
Free quote · Ships nationwide
Quote Custom 5-Panel Hats
Model, color, quantity, decoration and your logo (attach it below). We reply with pricing and a mockup, usually within one business day.
Logo files: .ai, .eps, .pdf, .svg or a high-res .png. Prefer to talk it through? Call 775-230-0211 or email sales@battlebornclothing.com.
Frequently Asked Questions
What is a 5-panel hat?
A cap built from five panels, with one wide panel across the front instead of two. There is no seam down the middle of the front.
Why choose a 5-panel hat for a patch?
With no center seam, a leather or woven patch lies flat and the logo is not split. It is the most popular shape for leather patch hats.
Can you do 3D puff on a 5-panel hat?
Yes, on structured 5-panels like the Blackhawk and 6006. Keep puff letters bold and simple.
Do you sell Zapped hats blank?
Yes. Every Zapped model can be bought blank on our store, or decorated with your logo. Most blanks are $24.99; Elite models are $32.99.
How long do custom Zapped hats take?
Standard production is 10–14 business days from your approved proof, plus shipping. Rush is available depending on the schedule.
Is there a minimum order?
No minimum on embroidery or patches. Pricing improves at 12, 48 and 144 pieces.
How long does a custom hat order take?
Standard production is 10–14 business days from your approved proof, plus shipping. Rush is available depending on the schedule.
Do you ship outside Nevada?
Yes. We decorate in Yerington, Nevada and ship custom caps anywhere in the US.
Cap Guides
Compare Other Cap Models
Shop every blank in the Zapped Headwear collection, or see all Zapped models, 5-panel hats, 7-panel hats and every cap compared.
Everything else for hats: bulk embroidered hats · shop hats, caps and beanies · wholesale hats nationwide · pricing · logo design · request a quote.