The Art of Customizing New Era Hats
New Era Cap Company has been manufacturing headwear since 1920, and their fitted caps have become iconic fashion accessories that transcend sports and streetwear culture. While the company offers an enormous selection of designs, colors, and collaborations, many hat enthusiasts want to take things a step further by creating truly unique, personalized pieces. Customizing a New Era hat allows you to express your individuality, commemorate special events, promote a brand or business, or simply create a one-of-a-kind accessory that nobody else owns.
The customization possibilities for New Era hats are remarkably diverse. From simple modifications like swapping out the brim or adding a patch to more complex techniques like custom embroidery, hand painting, and rhinestone embellishment, there is a customization method suited to every skill level and budget. Whether you are creating a hat for personal use, as a gift, or as merchandise for a brand, understanding the available techniques and best practices will help you achieve professional-quality results.
Choosing the Right Base Hat
The foundation of any custom New Era hat project is selecting the right blank or base hat. New Era offers several cap styles, each with its own characteristics and customization potential. The 59FIFTY is the classic fitted cap, featuring a structured crown, flat brim, and iconic silhouette that has been the standard for Major League Baseball since 1954. This style is the most popular choice for customization due to its premium construction and timeless look.
The 9FIFTY is a snapback version of the 59FIFTY, offering a similar profile with an adjustable closure. This style is popular for customization projects where one-size-fits-most is preferred, such as promotional merchandise or retail collections. The 9FORTY is a more relaxed, curved-brim cap with a velcro or strapback closure, offering a casual alternative to the structured 59FIFTY and 9FIFTY styles.
When selecting a base hat for customization, consider the color of the cap, the material, and the existing design elements. Blank caps in solid colors provide the cleanest canvas for custom designs, while pre-existing logos or embroidery may need to be worked around or removed. New Era offers blank caps through their custom order program, and blank New Era caps can also be found through authorized distributors and specialty retailers.
Custom Embroidery Techniques
Embroidery is the most professional and durable method of customizing a New Era hat. Machine embroidery uses computerized sewing machines to stitch intricate designs, logos, and text directly onto the cap material. The result is a high-quality, long-lasting decoration that closely resembles the factory embroidery found on standard New Era caps.
To have a hat custom embroidered, you will need a digitized version of your design, which is a specialized file format that tells the embroidery machine exactly where and how to place each stitch. Embroidery digitizing software and services can convert artwork, logos, and text into embroidery-ready files. The quality of the digitization directly affects the quality of the finished embroidery, so it is worth investing in professional digitizing services for complex designs.
If you have access to an embroidery machine, you can embroider caps yourself with the appropriate cap hoop or frame attachment. Most modern embroidery machines accept cap frames that hold the cap securely during the stitching process. Practice on scrap material or inexpensive caps before working on your New Era hat, as mistakes in embroidery can be difficult or impossible to correct.
Hand embroidery is another option for those who prefer a more artisanal approach. While more time-consuming than machine embroidery, hand embroidery allows for unique textures, dimensional effects, and a handcrafted aesthetic that machine embroidery cannot replicate. Popular hand embroidery techniques for caps include chain stitch, satin stitch, and French knots.
Iron-On Patches and Appliques
Adding patches to a New Era hat is one of the easiest and most versatile customization methods. Iron-on patches can be applied to the crown, sides, or back of the cap and come in an infinite variety of designs, from sports logos and military insignia to custom-made patches featuring your own artwork. This method is accessible to beginners and requires minimal tools and expertise.
To apply an iron-on patch to a New Era hat, position the patch on the desired location and cover it with a thin pressing cloth. Use a household iron set to the appropriate temperature (usually medium-high without steam) and press firmly for the time specified in the patch instructions, typically 15 to 30 seconds. Allow the patch to cool completely before handling the hat. For added security, consider stitching around the edges of the patch with a needle and thread, especially for patches that will be exposed to frequent handling or washing.
Custom patches can be ordered from numerous online services that allow you to upload your own design and choose the size, shape, border style, and backing type. Minimum order quantities are often as low as a single piece for custom patches, making this a viable option for one-off projects as well as larger productions.
Hand Painting and Fabric Markers
Hand painting a New Era hat is a popular customization method that allows for unlimited creative expression. Artists and customizers use fabric paints, acrylic paints formulated for textiles, and paint markers to create original designs ranging from simple patterns to detailed illustrations on the cap's surface.
Before painting, prepare the cap surface by cleaning it with a damp cloth to remove any dust or oils. If the cap has a dark color, a light-colored base coat may be necessary for your design to show clearly. Use fabric-specific paints that are designed to be flexible and durable on textile surfaces, as regular acrylic paints may crack or peel over time due to the flexibility of the cap material.
Apply paint in thin layers, allowing each layer to dry completely before adding the next. This technique prevents bleeding and ensures clean lines and vibrant colors. For detailed work, use fine-tipped fabric markers or small artist brushes. After the design is complete and fully dry, heat-set the paint according to the manufacturer's instructions, usually by applying heat with a heat gun or iron. This step makes the paint permanent and washable.
Stencils can be helpful for creating clean, repeatable designs, especially text and geometric patterns. Create your own stencils from cardstock or plastic, or purchase pre-made stencils from craft supply stores. Secure the stencil to the cap with temporary adhesive spray or tape, and apply paint using a dabbing motion rather than brushing to prevent paint from bleeding under the stencil edges.
Brim Customization and Under-Brim Art
The brim of a New Era hat offers additional customization opportunities. Under-brim art, where a design is painted or printed on the underside of the brim, has become a popular trend in custom hat culture. This hidden design element is revealed when the hat is removed or tilted, adding a surprise element to the customization.
Brim painting follows the same techniques as crown painting, with special attention to the flat surface of the brim, which can be easier to work with than the curved crown. Some customizers also modify the brim itself by reshaping it from flat to curved or vice versa, or by replacing the standard brim with an alternative material such as leather, suede, or printed fabric.
Brim replacement is a more advanced modification that involves carefully removing the existing brim from the cap and attaching a new one. This process requires sewing skills and the right equipment, as the brim must be securely attached to maintain the structural integrity of the hat. Custom brim materials can be sourced from fabric stores or specialty suppliers.
New Era's Official Custom Program
New Era offers an official customization program called New Era Custom, which allows individuals and organizations to design custom caps directly through the company. This program offers access to New Era's full range of cap styles, colors, and materials, along with professional embroidery and printing services. The program is ideal for team orders, corporate merchandise, special events, and retail collections.
Through the New Era Custom program, you can choose every aspect of your cap design, including the cap style, color, fabric, closure type, embroidery placement, thread colors, and additional details like side patches and back embroidery. Minimum order quantities apply, which vary by product and customization options selected. While this program is typically more expensive than DIY customization, it offers the highest quality results with factory-level precision and durability.
Caring for Your Custom Hat
Proper care will help preserve the custom elements of your New Era hat and extend its lifespan. Avoid machine washing custom hats, as the agitation and water can damage paint, embroidery, and patches. Instead, spot clean with a damp cloth and mild soap, gently working on stained areas without excessive rubbing. For heavily soiled hats, hand washing in cool water with a gentle detergent is preferable to machine washing.
Store your custom hats on a hat rack, in a hat box, or on a hat form to maintain their shape. Avoid stacking heavy items on top of your hats, as this can crush the crown and distort the shape. Keep hats away from direct sunlight when not in use, as prolonged UV exposure can fade colors and degrade paint and thread over time. With proper care and storage, a well-customized New Era hat can remain a prized accessory for many years.
