How To Design a Custom Beanie
Whether you're launching a new merch line or outfitting a team, designing a custom beanie is more than just choosing colors and uploading a logo. At Fourbital Factory, every hat is built in Burlington, Vermont, using a streamlined design process that ensures premium quality, fast turnaround, and full customization—right down to the stitch. Here’s how to create your perfect custom beanie.
1. Choose Your Beanie Style
At Fourbital Factory, you start by selecting your base style: Ribbed Knit or Jacquard Knit, and your preferred fit—Skully, Midi, or Cuffed.
Jacquard Beanies knit your design directly into the fabric—perfect for logos, repeating patterns, and bold, integrated visuals that stretch without distortion.
Ribbed Knit Beanies offer a classic, stretchy texture that works well with embroidered or woven logos and more minimalist styling.
2. Pick Your Yarn & Color Palette
With access to over 25 yarn colors, you can choose solid or heathered shades—or collaborate with the design team on a custom blend that matches your brand or event palette.
3. Add the Finishing Touches
Here’s where your beanie becomes one-of-a-kind:
Design Submission: You can send your own concept or logo, or choose to work with Fourbital’s design team on your idea.
Pom-Pom Options: Choose between classic pom-tops or no-pom styles.
Custom Labels: Select woven tags, embroidery, or leather patches for subtle—or standout—branding.
Personalization: Add names, event details, or team messages as needed.
4. Approve the Design & Mockup
Once your style, colors, and branding are selected, Fourbital provides a proof or mockup to review. For ODM-style orders, they help guide the design; for OEM-style orders, you supply the design and Fourbital builds to your specifications. Learn about the difference between ODM and OEM for when it comes to designing custom beanies.
5. Production & Manufacturing
All production happens under one roof in Vermont, ensuring ethical labor, domestic quality control, and a truly tariff‑proof process.
Standard production timeline is 2–6 weeks, depending on order size and customization complexity—plus approximately 1–5 days for shipping.
6. Shipping & Delivery
Once complete, your order ships directly from Vermont. Expect reliable U.S. fulfillment—no customs delays or surprise tariffs. Orders are typically delivered within a few business days.
Why This Process Works
Made-In-USA Quality
Manufactured entirely in Vermont, Fourbital avoids overseas delays and offers direct communication from beginning to end. Every beanie reflects U.S. labor standards and quality control.
Low Minimum Orders & Fast Lead Times
Whether you're ordering 50 hats or 500, Fourbital offers scalable solutions with quick turnaround. This flexibility is perfect for startups, events, limited product runs, or pilot programs.
Sustainable & Transparent
Fourbital is committed to eco-conscious practices: from recycled or responsibly sourced yarns to low-waste production. Their transparent Vermont-based facility means you know how—and where—your products are made.
Quick Design Checklist:
| Step | Action |
|---|---|
| 1 | Choose Ribbed or Jacquard style (Skully, Midi, Cuffed) |
| 2 | Pick yarn colors (25+ available or custom blend) |
| 3 | Add custom elements: pom‑pom, tags, embroidery, labels |
| 4 | Submit your logo or work with Fourbital for design help |
| 5 | Review and approve mockup |
| 6 | Production (2–6 weeks) and shipping (1–5 days) |
At Fourbital Factory, designing a custom beanie isn't just about picking design elements—it’s about crafting a product that reflects your brand values and identity. Every step, from style selection to finished knit, is handled in-house in Vermont, so you get reliability, speed, and transparency.
Whether you're building your first merch line or launching a limited drop, this process ensures your custom beanie is a wearable product you can feel proud to stand behind.
Ready to get started? Get a quote today!