Custom Caps & Headwear Manufacturer
- Est. 2005 · Sialkot, Pakistan
- MOQ 20–25 pcs per design · no limit for brands
- Free 24h digital mockup
- Sample 5–7 days, credited on bulk
- Bulk 15–25 business days · express 7–12
- DHL/FedEx/UPS 5–10 days
- 🛡️ Free remake within 3 days
ZipaSports is a custom caps and headwear manufacturer and supplier in Sialkot, Pakistan — our own factory since 2005 — producing embroidered baseball caps, snapbacks, trucker caps, bucket hats, beanies and sports visors for sports clubs and teams, schools and academies, gyms and studios, startup clothing brands and distributors, from 20–25 pieces per design, with a free 24-hour digital mockup and a free remake on any manufacturing defect.
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.
What happens if my caps & headwear apparel arrive with a defect?
Quality Guarantee: if any garment arrives with a manufacturing defect, we remake it free of charge — the remake goes into production within 3 days of your report. Send photos and your order reference within 7 days of delivery; replacement pieces are shipped to you at no charge, or we issue a credit if you prefer. Full policy: Quality Guarantee.
Do you make caps & headwear apparel for startup brands, clubs and academies?
Yes. ZipaSports manufactures custom caps & headwear apparel in Sialkot, Pakistan for startup and established sportswear brands (no MOQ limit for brands), for clubs and teams from 20–25 pieces per design, and for academies, schools, gyms and studios — each order carries your own crest, colours, names, numbers and labels.
Are you a caps manufacturer or a trading company?
ZipaSports is the factory. Every cap and hat is panelled, embroidered or printed, sewn and inspected in our own facility in Sialkot, Pakistan, in production since 2005. You deal with the production team directly, not an agent, and you can request pre-shipment photos or a video tour.
Can a new clothing brand order private-label caps from you?
Yes. We produce private-label and OEM headwear with your own woven neck or inside labels, printed size tags, hang tags and branded polybags. Send a logo, sketch or reference and our studio returns a free digital mockup within 24 hours, with unlimited revisions before approval.
Which headwear can you manufacture?
We make six-panel structured caps, snapbacks, fitted flat-peak caps, trucker caps, dad hats, five-panel camp caps, bucket hats, beanies, visors, sun hats, headbands, sweatbands, neck gaiters and balaclavas. Decoration options include embroidery, sublimation, screen print, DTF and applied patches.
Where is your cap factory and do you export to the UK and USA?
Our factory is in Sialkot, Punjab, Pakistan, and we export worldwide. Express courier by DHL, FedEx or UPS takes 5–10 days and sea freight 3–6 weeks for bulk. Main markets are the UK, USA, Canada, Australia, Germany and the UAE.
Custom caps and headwear, embroidered and sewn in our own factory
Caps & Headwear buyers reach ZipaSports with many phrasings — custom caps manufacturer, custom headwear manufacturer, custom hats manufacturer, caps and hats supplier — and every one of them describes the same thing: a factory in Sialkot, Pakistan that designs, prints, sews and inspects caps under one roof since 2005.
Headwear supplier for clubs, academies, gyms and clothing brands
We supply caps to clubs and teams, academies and schools, gyms and studios, distributors and resellers, and to startup brands launching their first range — custom caps for football clubs, team headwear for schools and academies and caps manufacturer for startup clothing brands. The minimum is 20–25 pieces per design, lower on request, with no MOQ limit for established brands.
Wholesale and private-label caps, beanies, bucket hats and visors
Wholesale and private-label production run through the same lines: your woven labels, size tags, hang tags and packaging are applied in-house, and export documents are prepared for the UK, USA, Canada, Australia, Europe and the GCC — custom caps manufacturer Pakistan, headwear manufacturer Sialkot. Every order carries the quality guarantee: a manufacturing defect is remade free of charge, with the remake in production within 3 days of your report.
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Who orders custom caps & headwear apparel? Startups, clubs, academies & more
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Why source bags & accessories from Sialkot, Pakistan
Bag manufacturing is in-house at ZipaSports: 600D polyester and 420D nylon kit bags, backpacks and duffles matched to the team's kit colours. ZipaSports has run every stage — design, sublimation, cutting, stitching, embroidery, QC and packing — in one factory here since 2005, with 0% import duty into the UK and EU on apparel made in Pakistan.