Picking a hat is easy. Getting the size right is where people trip up, especially when you're ordering custom caps for a whole group. The good news is that measuring your head takes about two minutes, and most custom hats are forgiving about it. Here's how to do it, a full size chart, and what actually matters when you order.
How to measure your head for a hat
- Grab a soft tape measure, or a piece of string and a ruler.
- Wrap it around the widest part of your head, about an inch above your ears and across the middle of your forehead. That's where a hat sits.
- Keep it snug but not tight. One finger should fit under the tape.
- Read the number in inches or centimeters. If you used string, mark where it overlaps and measure that against a ruler.
That measurement is your head circumference. Match it to the chart below to find your hat size.
Hat size chart
| Head (inches) | Head (cm) | Fitted size | S to XL |
|---|---|---|---|
| 21 1/4 | 54 | 6 3/4 | S |
| 21 5/8 | 55 | 6 7/8 | S/M |
| 22 | 56 | 7 | M |
| 22 3/8 | 57 | 7 1/8 | M/L |
| 22 3/4 | 58 | 7 1/4 | L |
| 23 1/8 | 59 | 7 3/8 | L/XL |
| 23 1/2 | 60 | 7 1/2 | XL |
| 23 7/8 | 61 | 7 5/8 | XL |
Which sizes do you actually need?
It depends on the cap's closure, and for most custom orders this is where it gets easy:
- Snapback (adjustable): one size fits most adult heads, roughly 6 7/8 to 7 5/8. If you're buying for a group and don't want to collect sizes, this is the move. The Richardson 112 is the classic example.
- Flexfit (stretch): comes in ranges like S/M and L/XL. Snugger and more tailored, but you need a rough idea of head sizes. A simple rule: mostly L/XL for men's crews, an even split for mixed groups.
- Fitted: exact sizes (7, 7 1/8, and so on) with no adjustment. The cleanest look, but you need everyone's real size, so it's best when you can collect them up front.
We break down all three in the hat fit guide, and if you're still choosing a style, the hat styles guide covers trucker, dad, 5-panel and flexfit.
FAQ
What's the most common hat size?
For adult men it's around 7 1/4 to 7 3/8. For women it's around 7 to 7 1/8. That's why one-size snapbacks fit most people.
What if I'm between sizes?
Size up. A slightly loose fitted cap is more comfortable than a tight one, and an adjustable or flex cap takes up the slack.
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Ben B., founder of Embroidery Inc, Woodland CA