Top 5 Best Beanie Manufacturers in the USA (2025 Guide)

When it comes to sourcing high-quality, custom beanies, businesses and brands are increasingly looking for U.S.-based manufacturers. Why? Because American-made means shorter lead times, better communication, and products crafted with care. Whether you’re outfitting your team, launching merch for your brand, or looking for private-label options, working with a U.S. manufacturer ensures quality and consistency.

In this guide, we’ll highlight the top beanie manufacturers in the USA—companies known for craftsmanship, customization, and customer service. Let’s dive in.

1. Fourbital Factory – Vermont

Best for: Custom knit beanies, sustainable production, fast turnaround

At the top of our list is Fourbital Factory, a Vermont-based beanie manufacturer that’s redefining American knitwear. Specializing in fully customizable beanies, they combine old-school craftsmanship with modern style. Whether you’re ordering 50 beanies for your event or 5,000 for your merch drop, their in-house knitting operation ensures consistency and speed. Plus, every beanie is made with a focus on sustainability and local sourcing—no overseas delays, tariffs, or guesswork.

Standout features:

• Made 100% in Vermont

• Customizable: colors, tags, embroidery, and jacquard designs

• Low minimums

• No tariff worries

• Quick turnaround times

• Eco-conscious practices

2. Unionwear – Newark, NJ

Best for: Union-made products, government and promotional orders

Unionwear has been manufacturing American-made apparel and accessories for over two decades. Their beanie selection includes fleece and knit options, and they’re especially trusted for bulk government and union orders. If being "union-made" is important to your brand, Unionwear is a go-to.

3. Bayside Apparel – Anaheim, CA

Best for: Bulk blank beanies, resellers, private label

Known for their extensive blank apparel catalog, Bayside also offers knit caps and beanies all made in the USA. Their beanies are ideal for screen printing or embroidery, and they're often used by resellers or companies with in-house customization capabilities.

4. Royal Apparel – Hauppauge, NY

Best for: Organic materials, private label beanies

Royal Apparel emphasizes organic and eco-friendly textiles in their American manufacturing. Their blank beanies are made from organic cotton and can be customized through their private label program.

5. Rustek – Portland, OR

Best for: Natural fiber beanies, outdoor brands

Rustek produces a line of merino wool and organic cotton beanies sourced and sewn in the USA. They cater primarily to outdoor brands and eco-conscious consumers, offering low environmental impact with high-quality craftsmanship.

Why Choose a US-Based Beanie Manufacturer?

There are plenty of reasons to go domestic when choosing a beanie manufacturer:

• Faster Shipping: No 6–8 week lead times from overseas suppliers

• Customization Control: Work directly with your manufacturer to get exactly what you need

• Support Local Jobs: Buying American supports skilled workers and small businesses

• Smaller Carbon Footprint: Local sourcing and production = fewer emissions

• Quality & Trust: You know exactly where your beanies are coming from and how they’re made

How to Choose the Right Beanie Manufacturer

Before placing an order, consider the following:

• Minimum Order Quantities (MOQs): Some manufacturers require large orders; others are more flexible

• Customization Options: Embroidery, jacquard, patches, and woven labels vary by provider

• Material Preferences: Do you need organic cotton, merino wool, or synthetic fibers?

• Turnaround Time: Can they deliver in time for your event or launch?

• Sustainability Goals: Is eco-friendliness a priority?

What Sets Fourbital Factory Apart

At Fourbital Factory, we’re not just another beanie supplier — we’re your partners in custom headwear that’s designed, knit, and finished entirely in Vermont. What truly sets us apart is our commitment to local craftsmanship, sustainable practices, and hands-on service from start to finish. Unlike many overseas manufacturers, we’re not impacted by international tariffs or supply chain slowdowns, which means faster turnaround times, more predictable pricing, and total transparency. We offer low minimums, full customization (from jacquard to embroidery), and a quality-over-quantity approach that makes every beanie a piece of functional art. Plus, our nimble team is always just a phone call away — no automated hotlines, just real people who care about getting your project right.

Final Thoughts

Whether you're a brand looking for a merch partner or a business sourcing beanies for a team or event, working with a U.S.-based manufacturer ensures quality, reliability, and a smoother production process.

At Fourbital Factory, we’re proud to be part of the new generation of American manufacturers bringing creativity, craftsmanship, and community into every custom beanie we knit.

Ready to get started? Contact Fourbital Factory today to talk about your next custom beanie project.