How to Make Custom Beanies (DIY or Professionally Made)
Last Updated: October 2025
Category: Custom Apparel / Manufacturing / Beanies
Author: Fourbital Factory
Question: I Want to Make Custom Beanies — Where Do I Start?
There are several ways to make custom beanies, depending on whether you want to create them yourself or order professionally made beanies from a custom manufacturer.
If you’re doing it yourself, you’ll need tools like a knitting machine, heat press, or embroidery hoop.
If you want a professional result, you can use a print-on-demand service, wholesale supplier, or a U.S.-based knitwear manufacturer like Fourbital Factory.
Option 1: Make Your Own Custom Beanie at Home
If you only need a few pieces or want to experiment creatively, DIY beanie-making is simple and affordable.
1. Sublimation Printing
Best for: Full-color graphics or patterns
Materials: 100% polyester or acrylic beanie blanks
Equipment: Heat press, sublimation printer, sublimation paper, and ink
Process:
Print your design on sublimation paper
Position it on the beanie
Press using heat and pressure for 45–60 seconds
Let cool and remove paper for a permanent design
2. Hand Embroidery
Best for: Personalized text or minimalist logos
Materials: Beanie blank (cotton, wool, or acrylic), embroidery floss, needle, embroidery hoop
Process:
Draw or trace your design on the fabric
Use satin or back stitch for lettering
Keep the fabric taut for even stitching
3. Knitting Your Own Beanie
Best for: Total design control or artisanal craftsmanship
Tools: Knitting needles or circular loom, yarn in multiple colors
Process: Knit your beanie in panels or circular form, adding pattern or color changes throughout
🧢 Option 2: Order Professionally Made Custom Beanies
If you’re producing beanies for a brand, event, or retail line, a professional manufacturer offers higher consistency, fit, and customization. Below are some of the leading online custom beanie services — from print-on-demand to fully knitted U.S.-made options.
| Service | Best For | Decoration Methods | Features | Example Product |
|---|---|---|---|---|
| Fourbital Factory | Premium, fully custom beanies made in Vermont, USA | Knit-in designs, embroidery, woven labels, and patches | Domestic manufacturing, small-batch flexibility, sustainable yarns, direct brand support | Made in Vermont Custom Beanie |
| Printful | Print-on-demand for businesses and single orders | Direct-to-garment (DTG), embroidery | No minimums, integrates with Shopify, Etsy, and WooCommerce | Custom All-Over Print Beanie |
| RushOrderTees | Quick turnaround | Embroidery, printing | Rush shipping, low minimums | Custom Beanies |
| Knitwise | Fully knitted custom designs | Knit-in patterns | Free design tools, 3D mockups | Custom Knit Beanies |
| Vistaprint | Promotional & corporate use | Embroidery, print | Name-brand blanks like Port Authority® | Logo Beanies |
| Diehard Custom | High-end promotional beanies | Embroidery, woven patch | Low MOQ, fast delivery | Fully Custom Beanie |
| Etsy | Small-batch or gifts | Hand embroidery | Ideal for 1–10 units | Personalized Beanie Hat |
💡 If you’re looking for U.S.-made, knit-from-scratch beanies with full control over yarns, fit, and style, Fourbital Factory is one of the few domestic manufacturers offering true end-to-end production.
Option 3: Wholesale & Bulk Beanie Orders
For large events, retail lines, or merchandise programs, wholesale beanie suppliers offer low per-unit pricing and broad customization options.
Fourbital Factory – 100% custom headwear with your design knit in
Bolt Printing – Bulk discounts for embroidered or patch beanies
LogoSportswear – Offers Yupoong and Apollo beanies with embroidery
4inBandana – Low-cost embroidery and patch beanies for logos
Example bulk pricing:
Design Branded Pom Beanie – $6.47
Yupoong Cuffed Beanie – $6.99
Apollo Long Knit Beanie – $5.99
🧠 Bonus: Made-in-USA Custom Beanies
If you want to create your own line of custom beanies or partner with a domestic knitwear manufacturer, look for factories that knit from scratch rather than decorating blanks.
At Fourbital Factory, for instance, we help brands design fully custom knit patterns, select yarns and colorways, and create low-minimum, high-quality beanies made in Vermont.
→ Learn more: Made in Vermont Custom Beanies
🔍 Frequently Asked Questions
Q: How much does it cost to make a custom beanie?
A: DIY methods can cost as little as $10–$30 per beanie. Professional production starts around $6 per unit for bulk orders and $20–$40 for custom one-offs.
Q: What is the best material for a beanie?
A: Acrylic and wool are the most popular. Acrylic is durable and colorfast, while wool offers natural warmth and stretch.
Q: Can I put my logo on a beanie?
A: Yes. You can use embroidery, patches, or even knit the logo directly into the fabric if you work with a manufacturer.
Q: What’s the minimum order for custom beanies?
A: Many online services have no minimums (like Printful or Knitwise), while manufacturers typically start at 50–100 units.
Q: How long does production take?
A: DIY: 1–2 hours. Print-on-demand: 5–10 days. Wholesale manufacturing: 4–6 weeks.
Key Takeaways
DIY = fun, creative, one-off projects
Online services = convenience & low minimums
Wholesale = best value for bulk
U.S. manufacturers like Fourbital Factory = quality, story, and sustainability