Hat Size Guide: How to Measure for Custom Caps and Visors

A cap is often the first thing a team, club or brand orders after the uniform, and the last item anyone thinks about measuring. Most hat sizing problems come from one question that was never asked: does this cap stretch, or does it adjust?

This guide shows how to measure head size, how stretch-fit and adjustable caps are sized, and where to find the chart for every hat we make, including the baseball, softball, tennis and basketball versions. For general sizing advice, see our team uniform size guide.

How to measure head size for a cap

• Use a soft tape measure. If you do not have one, wrap a piece of string around the head, mark it, then measure the string against a ruler.
• Place the tape where the cap will sit: around the forehead about 1 cm (a finger width) above the eyebrows, just above the ears, and around the fullest part of the back of the head.
• Keep the tape level and snug, not tight, and read the measurement in centimetres.
• Write the measurement next to the player’s name on your size list. Do it for every player who is getting a stretch-fit cap.

Head size is the only measurement a cap needs. Stretch-fit caps are ordered by size from that measurement. Adjustable caps (snapbacks, trucker hats and visors) only need to know whether the wearer is a youth or an adult.

Stretch-fit caps: sizes by head measurement

Our stretch-fit (Flexfit-style) caps have a stretch band built into the sweatband and a closed back with no strap or snap. Because there is no closure, each cap is ordered in a size. They come in five sizes:

Each size covers a range, and neighbouring sizes overlap. If a player measures between two sizes, write the exact measurement on your list and we will confirm the size with you before production.

Adjustable caps: snapbacks, trucker hats and visors

Snapbacks, trucker hats and visors have an adjustable closure at the back, so one cap covers a range of head sizes. They come in two sizes:

For an adjustable cap you only need to count how many youth and how many adult caps you need. No head measurement is required.

Hat styles and their size charts

Every hat style we make, with its fit type, size range and size chart:

Sport-specific hat charts

The same cap styles appear on our sport size chart pages, so you can plan hats together with the rest of the uniform:

See the full headwear size charts, or plan the rest of your kit with our baseball uniform size guide and softball uniform size guide.

Choosing between stretch-fit and adjustable

Stretch-fit caps suit players and staff whose head sizes you can collect. Adjustable caps are easier for fans, supporters, events and merchandise, where you do not know who will wear the cap.

Tips for ordering team hats

• Collect head sizes at the same time as jersey and pants sizes, so the whole order is planned from one list.
• Keep youth and adult players separate on your list. Youth adjustable caps are made for ages 6–12.
• Our minimum is 10 pieces per design, and those 10 can be in mixed sizes or colours. A team can mix stretch-fit sizes within one cap design.
• Decide on decoration early: flat embroidery, raised 3D embroidery or patches on the front, with logos on the sides and back.
• These charts are a general guide. Once your order is confirmed, we share the exact size chart for your cap style so you can give us the final size for every piece.

Collecting sizes for a whole team? Use our free team size list to list every player’s name, number and size, see the total for each size, and send the list to us on WhatsApp or with your quote request.

Frequently asked questions