Premium stitched caps, beanies, and buckets. Executed on high-speed Tajima machinery with 3D Puff capabilities.
We help you select the exact headwear profile for your brand. From premium AS Colour surf caps to heavy-duty Flexfit truckers engineered for trades.
Caps require specific decoration methods based on the crown structure. We recommend 3D Puff Embroidery for structured snapbacks, and flat stitch or woven patches for unstructured dad hats.
Your artwork is converted into a cap-specific stitch file. We engineer the thread pathing from the centre out to ensure the logo wraps perfectly around the curved crown without puckering.
Caps are loaded onto specialised curved hoops on 6-head Tajima embroidery machinery. High-tension stitching for a permanent finish that doesn't crack, peel, or fade.
Every cap is inspected for thread tension and alignment, then boxed securely so the crowns don't crush in transit.
A high-density foam is placed under the stitching to create a heavy, raised, dimensional effect. It's the premium retail standard for structured caps and snapbacks. Min 50 units, 2-3 week turnaround, quoted separately to standard flat embroidery.
Standard caps (AS Colour, Grace Collection, Yupoong) start at 10 units. Flexfit caps require 25 units minimum due to supplier sizing run requirements. Same logo and thread colour can be split across different cap colours.
Yes. We have specialized hoops that allow us to embroider on the sides and the rear arch (above the snap/strap). Each additional location incurs a separate print cost.
Yes. Woven and PVC patches are a massive trend for workwear and streetwear. They require a slightly longer turnaround time (15-20 days) as they are custom manufactured before being applied to the cap.
We supply the industry heavyweights: Flexfit (Yupoong) for premium streetwear and sports, AS Colour for retail fashion, and Grace Collection for budget-friendly promo runs.
Yes. Your digitized stitch files are securely held on our server. Reordering for new hires is a fast, streamlined process with zero new setup fees.
[ BASELINE: STANDARD CAP (AS COLOUR / GRACE COLLECTION) // FRONT-CENTRE LOGO // ~8K STITCH COUNT ]
[ FLEXFIT 25 MOQ // 3D PUFF QUOTED SEPARATELY (50 MOQ, 2-3 WEEK TURNAROUND) // PREMIUM BRANDS (NEW ERA, ETC.) PRICED HIGHER ]
We don't do one-offs. Our infrastructure is built to manage massive headwear runs for national trades and retail brands.
Transparent pricing, hard deadlines, and we'll tell you if your artwork won't stitch well on a curved crown before you pay.
You deal directly with our Melbourne team. We handle the production pipeline end-to-end - one point of contact from blank selection to delivery.
Used Melbourne Merch for Merch for my daughter who's a Musician. Not only were Joe & Chris easy to deal with, they were fast with email reply's, mock up's and help full with any questions I had. The Merch arrived when they said it would and what fantastic quality it all is. The p...
Joanne Brain
a year ago
On behalf of CIEE Melbourne, we had an excellent experience working with Melbourne Merch and especially Joe, who took care of our recent t-shirt order. Joe Giampa was incredibly professional, patient, and supportive throughout the entire process. From refining our designs to mana...
Tharidhu Peries
5 months ago
Outstanding service and top-quality tees! I ordered custom T-shirts from Melbourne Merch for a team event and couldn’t be happier. The turnaround was quick, the print quality was excellent, and the shirts themselves were really comfortable. The team was easy to deal with—straight...
Reecha Kumari
6 months ago
Tell us about your headwear run. Quote within 24 hours, 10-12 day turnaround on standard flat embroidery.
