Custom Caps & Headwear Manufacturer
ZipaSports manufactures custom caps, beanies and headbands in Sialkot, Pakistan, from 20-25 pieces per design with 15-25 business day production. Headwear is the most common add-on line in the orders we run: a club adds embroidered caps to its kit order, a gym adds beanies to a merchandise range, and a distributor stocks headbands under its own label. Every piece is cut, sewn and decorated in-house to your artwork.
Structured caps are built from polyester or poly-cotton twill panels with a stiffened peak, while sublimated caps use 100% polyester so all-over prints dye into the fibre instead of sitting on the surface. Beanies are knitted with a fold-over cuff that takes embroidery cleanly, and headbands use sweat-wicking polyester-spandex stretch knit. Decoration methods include multi-head embroidery, 3D puff print, screen printing, DTF transfer and woven rear labels, with colours matched to Pantone references.
Buyers include clubs finishing a teamwear order, brand owners building a merchandise line, and wholesalers ordering headwear in volume. Send a logo or a rough idea and our studio returns a free digital design mockup within 24 hours; a physical sample follows in 5-7 days, charged at sample cost and credited against your bulk order. Production runs in our Sialkot factory and ships worldwide by DHL, FedEx or UPS in 5-10 days.
🧢 Caps & Headwear Products
Ordering Details
| Fabric options | Polyester or poly-cotton twill caps; 100% polyester for sublimated designs; knitted beanies with embroidery cuff; polyester-spandex headbands |
|---|---|
| Decoration | Multi-head embroidery, 3D puff print, screen printing, DTF transfer, sublimation, woven rear labels |
| Typical order profile | Club and gym add-on runs 25-100 pieces; brand and distributor runs 200-1,000+ |
| Minimum order | 20-25 pieces per design; lower on request; no MOQ limit for sportswear brands |
| Sampling | Free digital mockup in 24 hours; physical sample 5-7 days at cost, credited on bulk order |
| Production time | 15-25 business days after design approval; express 7-12 days at additional cost |
| Shipping | Worldwide from Sialkot - DHL/FedEx/UPS express 5-10 days; sea freight for bulk |
Frequently Asked Questions
What is the minimum order for custom caps and headwear?
20-25 pieces per design. Lower quantities are possible on request, and there is no MOQ limit for sportswear brands and companies.
What are custom caps and beanies made of?
Caps are made from polyester or poly-cotton twill panels, with 100% polyester used for sublimated designs so the print dyes into the fibre. Beanies are knitted with a fold-over embroidery cuff, and headbands use polyester-spandex stretch knit. Exact composition is confirmed on your quotation.
How much do custom caps cost to manufacture?
Pricing depends on construction, decoration method and quantity - an embroidered six-panel cap prices differently from an all-over sublimated one. Send your design on WhatsApp and we return a quote within 24 hours; payment terms are confirmed with your enquiry.
How long does headwear production take?
Bulk production takes 15-25 business days after design approval. Express production in 7-12 days is available at additional cost, and a free digital mockup is delivered within 24 hours of your enquiry.
Do you ship custom headwear to the UK and USA?
Yes. We ship worldwide from Sialkot, Pakistan by DHL, FedEx or UPS in 5-10 days. Our main headwear markets are the UK, USA, Canada, Australia, Germany and the UAE, with sea freight available for bulk orders.
Can caps and beanies carry our own brand labels?
Yes. We produce full private-label headwear: embroidered or printed front logos, woven rear labels, printed size tags, hang tags and branded polybags, with every colour matched to your Pantone references.