Custom Zapped Headwear Hats: Every Model, Blank or With Your Logo
Short answer: Zapped Headwear makes premium, military-named caps: water-repellent 5-panel Blackhawks, 7-panel Ospreys, canvas Patriots and Gunnys, plus dad hats, truckers, boonies and beanies. Most blanks are $24.99. We add your logo with embroidery (about $8), 3D puff (about $10) or a laser-engraved leather patch ($4–$8), with no minimum.
Why Zapped Hats
Zapped caps are built for people who work and play outside. Many models have a water-repellent shell, the Blackhawk has perforated vent holes, and the Elite versions use a stretch nylon/spandex fabric. The 5- and 7-panel models have one seamless front panel, so a patch or wide logo sits flat with no seam through it. That makes them a favorite for leather patch hats, outdoor brands, ranches, contractors and guides.
5-Panel Models
| 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 |
More on choosing one: custom 5-panel hats.
7-Panel Models
| 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 |
More on choosing one: custom 7-panel hats.
6-Panel, Dad Hat and Trucker Models
| Model | What It Is | Blank |
|---|---|---|
| Captain | Unstructured dad hat, water-repellent shell, curved bill, strap back | $24.99 |
| Cobra | Flat-bill snapback, structured poly face, trucker mesh; camo options | $24.99 |
| Bomber | 6-panel performance cap | $24.99 |
| Apache | Low-medium profile with a smaller curved bill | $24.99 |
| Warrior | 6-panel trucker, curved bill | $18.00 |
| General | High-profile flat bill | $12.00 |
Boonies, Crushables and Beanies
| Model | What It Is | Blank |
|---|---|---|
| Titan | Crushable cap that packs flat | $19.99 |
| Ranger | Perforated boonie / bucket hat | $24.99 |
| Knitted Cuff Beanie | Cuffed knit | $20.00 |
| Heather Cuff Beanie | Two-tone heather cuff | $20.00 |
| Waffle Beanie | Waffle knit, popular with leather patches | $20.00 |
| Woven Camo Cuff Beanie | Camo knit cuff | $24.99 |
| Pattern Cuff Beanie | Patterned knit cuff | $18.00 |
More knit options: custom beanies in bulk.
Pick a Zapped Hat by Use
| If you want… | Choose |
|---|---|
| An outdoor cap that sheds rain and breathes | Blackhawk or Blackhawk Elite |
| The biggest patch or a wide logo | Osprey (7-panel, flat bill) |
| A rugged canvas look | Patriot, Patriot Waxed or Gunny |
| The rope-cap trend | Any R+ model, or the Commodore |
| A relaxed dad hat | Captain |
| Camo and a flat bill | Cobra |
| The lowest cost per hat | General ($12) or Warrior ($18) |
| Bigger or smaller heads | XL and Youth Blackhawk and Osprey |
| Sun coverage | Ranger boonie |
What a Finished Zapped Hat Costs
| Example | Per Hat |
|---|---|
| Blackhawk + leather patch (glued) | $28.99–$32.99 |
| Blackhawk + leather patch (sewn) | $32.99–$36.99 |
| Osprey + flat embroidery | About $32.99 |
| Patriot + 3D puff | About $34.99 |
| General + flat embroidery | About $20 |
Blank plus decoration, before one-time digitizing (from $16.99). Larger runs are quoted lower; your quote confirms stock and price.
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 Zapped 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 Zapped Headwear?
A premium cap brand known for water-repellent, perforated and canvas hats named after U.S. military ranks and aircraft: Blackhawk, Osprey, Patriot, Gunny, Captain, Cobra and more.
Are Zapped hats good for leather patches?
Yes. The 5- and 7-panel models have a seamless front, so a laser-engraved leather patch sits flat. Our patches are $4–$8 per hat, bonded with an industrial adhesive that has yet to fail across thousands of hats, or sewn on for $4 more.
Can you embroider a water-repellent Zapped hat?
Yes. We embroider and 3D puff the front, side and back of water-repellent Zapped caps, or add a leather patch.
What is the difference between Blackhawk and Osprey?
Blackhawk is a 5-panel medium-profile cap with a precurved bill and vent holes. Osprey is a 7-panel cap with a flat bill and an even wider front for big logos.
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.