Bulk Trucker Hats: Custom Embroidered and Leather Patch Caps, 24 to 1,000+
Bulk Trucker Hats is a brand of Battle Born Clothing in Yerington, Nevada. We decorate Richardson, YP Classics, Flexfit and other mesh-back caps with embroidery or laser-engraved leather patches, from 24 pieces to pallet runs, and ship nationwide.
- No hard minimum
- 28-day turnaround
- Ships nationwide
- Patches since 2020
Bulk Trucker Hats makes one thing: custom trucker hats in quantity. Battle Born Clothing has made leather patches since 2020 on an 80-watt CO2 laser and runs two commercial embroidery heads in-house. We are an authorized decorator for Carhartt, Nike and OGIO, we redo our own errors for free, and standard turnaround is 28 days from proof approval. A Richardson 112 with your embroidered logo is $20.00 each at 48 and $18.50 at 144. The same hat with a laser-engraved leather patch is $20.50 at 48 and $18.50 at 144. Send artwork, a quantity and a style, and you will usually have a quote the same business day.
Trucker hat styles we decorate in bulk
Richardson 112
The standard bulk trucker: structured mid-profile, mesh back, snapback, 112 colorways.
From $18.50 each at 144 (embroidered or leather patch)
Details →
Richardson 112PFP camo
Printed five-panel camo front with mesh back. Custom camo hats in bulk.
Blank quoted per job; decoration from $5.00 each at 144
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Richardson 112FP
Five-panel version of the 112: solid front with no center seam, ideal for patches.
Blank quoted per job; decoration from $5.00 each at 144
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Richardson 115 low pro
Low-profile trucker for smaller heads and a lower, sleeker look.
Blank quoted per job; decoration from $5.00 each at 144
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Richardson 168 7-panel
Seven-panel, higher crown trucker with a big flat front for large patches and puff.
Blank quoted per job; decoration from $5.00 each at 144
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Richardson 312 twill back
A trucker shape with a twill back instead of mesh. For colder crews and a dressier look.
Blank quoted per job; decoration from $5.00 each at 144
Details →Bulk and corporate trucker hat orders (144 to 1,000+)
Large runs are where trucker hats get cheap per piece. At 144 pieces a Richardson 112 lands at $18.50 all-in with either embroidery or a leather patch. The blank stays $13.50; the decoration drops to $5.00. Above 144 the per-piece price holds and we schedule the run across both embroidery heads or the laser so the whole order ships together.
What a 250-hat order looks like
250 Richardson 112 caps, one front logo under 6,000 stitches: 250 × $18.50 = $4,625.00, plus $18.99 one-time digitizing. Mixed colors are fine. Split the 250 across up to a handful of 112 colorways with the same logo and the price does not change. Different logos or thread colors per group are priced as separate designs.
Mixing styles in one bulk order
You can mix styles (say, 112 for the crew and 115 low-pro for office staff) and we count the total quantity toward the price break as long as the decoration is identical. Blank prices differ by style, so each style gets its own line on the quote.
Corporate programs and reorders
We keep your digitized file and patch artwork on hand. Reorders skip the digitizing fee and go straight to proof. Battle Born Clothing does not run team or company online stores; we do straightforward bulk orders with one invoice and one ship-to (or a few).
Embroidered trucker hats
Flat embroidery on the front panel is the default for most bulk orders. We run a Happy HCD2-1501 and a YunFu 15-needle machine with Rapos thread. Logos up to 6,000 stitches are covered by the standard price; bigger fills are quoted per design.
Front logo
Standard placement is centered on the front panels. On a 112 the usable area is roughly 2.25 in tall by 4.5 in wide; we size the proof to the hat, not the other way around.
3D puff embroidery
Puff works on structured fronts like the 112, 168 and 511. It suits bold block letters and simple shapes, not thin lines. 3D puff is quoted per job because stitch counts and foam vary by design.
Side and back hits
A small side logo or back arch text is a second design and a second run through the machine. We quote it as an add-on per piece once we see the art.
Leather patch trucker hats
We cut and engrave leather patches in-house on an OMTech 80-watt CO2 laser. Patches are glued with a proprietary heat process on a two-platen VEVOR hat press, or sewn on request for $1 more per piece. Battle Born Clothing aims to be the top leather patch hat maker in the USA, and bulk trucker runs are a big part of that.
Patch shapes and sizes
Rectangles, rounded rectangles, ovals, circles, shields and custom outlines. Most front patches run 2 to 3.5 in wide. Send vector art and we will show you the patch at true size on the hat in the proof.
Glued vs sewn
Glued is standard and holds up to daily wear and washing. Sewn adds a visible stitch border and $1 per piece. Either way the patch price is $7.00 at 48 pieces and $5.00 at 144+.
Small runs (12 to 47 hats)
No hard minimum. Twelve hats is a real order here. Embroidery at 12-23 is $8.00 per hat on top of the blank; at 24-47 it is $7.00. Leather patch is $8.00 and $7.50 at the same tiers. Small runs follow the same 28-day schedule and get the same digital proof.
Customer-supplied hats
Bring your own caps and we add $2 per item handling to the decoration price. Industry-standard spoilage allowance is about 4 percent; we aim for zero and tell you up front if a style will not embroider well.
Why order bulk trucker hats from us
- Embroidery runs in-house on two commercial single-head machines (Happy HCD2-1501 and a YunFu 15-needle) with Rapos thread and Maggie magnetic frames.
- Leather patches made in-house since 2020 on an OMTech 80-watt CO2 laser, glued with our proprietary heat process on a two-platen VEVOR hat press, or sewn on request.
- No hard minimum on embroidery or leather patch. Price breaks every 24 pieces, down to $18.50 all-in on a Richardson 112 at 144+.
- Real style numbers and real blank costs. Richardson 112 blank is $13.50; YP Classics 6606 is $11.10. Blanks come from SanMar (Reno warehouse first) and S&S Activewear.
- Authorized decorator for Carhartt, Nike and OGIO, plus a Zapped Headwear dealer and direct Decky account.
- Standard turnaround is 28 days from proof approval. Rush is quoted per job, not guessed.
- Digital proof before production on every order. Free redo on our own errors.
- Customer-supplied hats welcome at $2 per item handling.
- Quotes usually go out the same business day. Battle Born Clothing, 3 Pebble Beach Dr, Yerington, NV. Ships nationwide.
How much do bulk trucker hats cost?
All-in means blank plus decoration, per hat. The table is for the Richardson 112 (blank $13.50) with a front logo under 6,000 stitches or a laser-engraved leather patch. Other styles follow the same decoration prices with a different blank cost. Battle Born Clothing prices break every 24 pieces.
| Quantity | Blank | Embroidery | Embroidered all-in | Leather patch | Patch all-in |
|---|---|---|---|---|---|
| 12-23 | $13.50 | $8.00 | $21.50 | $8.00 | $21.50 |
| 24-47 | $13.50 | $7.00 | $20.50 | $7.50 | $21.00 |
| 48-71 | $13.50 | $6.50 | $20.00 | $7.00 | $20.50 |
| 72-95 | $13.50 | $6.50 | $20.00 | $6.50 | $20.00 |
| 96-119 | $13.50 | $6.00 | $19.50 | $6.00 | $19.50 |
| 120-143 | $13.50 | $6.00 | $19.50 | $5.50 | $19.00 |
| 144+ | $13.50 | $5.00 | $18.50 | $5.00 | $18.50 |
How long does a bulk hat order take?
28 days from proof approval for standard orders. Rush is quoted per job.
Who orders bulk trucker hats from us
Contractors and crews
Company caps for the whole crew, reordered every season. Richardson 112 embroidered is the standard.
Read more →Breweries and taprooms
Hats that sell at the counter. Leather patch on a 112 or 6606 is the brewery standard.
Read more →Fishing and outdoor brands
Camo, patch and premium truckers for brands that sell hats as product.
Read more →Events and festivals
Staff, sponsor and giveaway hats on a date. Budget blanks and a fixed in-hands date.
Read more →Schools and teams
Team caps, booster fundraisers and coach gifts. 3D puff and flat bills included.
Read more →Agencies and merch resellers
Ship to your client, repeat clients, clean invoices. We are the shop behind your shop.
Read more →Frequently asked questions
What is the minimum order for bulk trucker hats?
There is no hard minimum on embroidery or leather patch. Pricing starts at the 12-23 tier and breaks every 24 pieces.
How much does a custom Richardson 112 cost in bulk?
Blank is $13.50. Embroidered all-in is $20.00 at 48 and $18.50 at 144, plus $18.99 one-time digitizing. Leather patch all-in is $20.50 at 48 and $18.50 at 144 with no setup fee.
How long does a bulk trucker hat order take?
Standard turnaround is 28 days from proof approval. Rush is quoted per job.
Do you make the leather patches yourselves?
Yes. Battle Born Clothing has cut and engraved leather patches in-house since 2020 on an OMTech 80-watt CO2 laser.
Are patches glued or sewn?
Glued is standard, using a proprietary heat process on a two-platen VEVOR hat press. Sewn is available for $1.00 more per hat.
Is embroidery or a leather patch cheaper?
About the same. Both run $5.00 to $8.00 per hat by tier. Embroidery adds $18.99 digitizing once per design; patches have no setup fee.
What artwork do you need?
Vector preferred (AI, EPS, PDF, SVG). A 300 dpi PNG works for embroidery. One-color line art for leather patches.
Do I get a proof?
Yes. A digital proof showing the logo or patch at size on the hat goes out before production on every order.
Can I mix hat colors in one order?
Yes. Same logo across any colors counts as one quantity for the decoration tier.
Can I mix hat styles in one order?
Yes. With the same decoration, styles count together toward the tier. Each style keeps its own blank price.
Get a bulk trucker hat quote
Tell us what you need and we'll price it from real blank costs and our decoration matrix. Quotes usually go out the same business day.