Custom 7-Panel Hats: Extra-Wide Fronts for Big Logos and Patches

Short answer: a 7-panel hat has the widest seamless front of any cap, so it fits big patches and long logos. We decorate the Zapped Osprey ($24.99, water-repellent, flat bill), the Osprey Elite ($32.99), the canvas Zapped Gunny ($24.99) and the Richardson 168 trucker. Embroidery is about $8 a hat, leather patches $4–$8, with no minimum.

Why 7 Panels

The extra panels let the front panel run wider and taller with no seam. A large leather patch or a long company name fits without wrapping onto the side seams. 7-panel caps usually have a flat or slightly curved bill and a modern, outdoor look.

Zapped 7-Panel Hats

Model	What It Is	Blank
Osprey	7-panel, medium profile, flat bill, water-repellent	$24.99
Osprey R+	Osprey with a rope across the bill	$24.99
Osprey Elite	90/10 nylon/spandex performance version	$32.99
Youth Osprey	Youth fit	$24.99
XL Osprey	Bigger fit for larger heads	$24.99
Gunny	7-panel canvas snapback in two-tone colors	$24.99

Other 7-Panel Caps We Decorate

Model	What It Is
Richardson 168	7-panel trucker with a seamless front and mesh back

For a slightly smaller front see 5-panel hats. Every Zapped model is on the Zapped Headwear page.

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 Purchase

Read all 45 reviews (4.6 average across Google, Etsy and our store)

Free quote · Ships nationwide

Quote Custom 7-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 7-panel hat?
A cap built from seven panels, with one large panel across the front. It gives the widest seam-free area for a logo or patch.

How big can a patch be on a 7-panel hat?
Larger than on a 6-panel cap, because there is no center seam to work around. We size the patch to the front panel of the model you pick and show it on your mockup.

Osprey or Gunny?
Osprey is a water-repellent performance cap with a flat bill; Gunny is a rugged two-tone canvas snapback. Both decorate well with embroidery or a leather patch.

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.