Our Process

Let’s make some killer hats.

Welcome to the Zephyr way! Here, we’re all about creating hats that don’t just look good—they feel good, fit right, and totally rep your vibe. Got an idea for a hat? Sweet. Want to stand out in a sea of basic caps? Even better. Here’s how we make it happen.

Contact us with your order details.

To begin your order, simply reach out to our team by filling out our Contact Form or calling our Customer Care line. One of our customization experts will reach out to learn more about your needs and help you bring your vision to life.

Design & customize

Once we’ve nailed the basics, it’s time for the fun part—designing your hat. We’re not here for boring; we’re here for unique, custom, one-of-a-kind hats that fit you, your team, or your brand.

Choose Your Style: Snapback? Flex-fit? Fitted? Yeah, we’ve got options. Pick a style that screams “you.”

Bring on the Colors: From bold colors to slick monochrome, your hat = your rules.

Proof’s In Your Inbox: We’ll whip up a digital proof for you to check out. Love it? Awesome. Want some tweaks? No problem—this is where you get exactly what you want.

We get to work

Once you give us the thumbs-up, our crew gets down to business, turning your digital dream into an actual hat.

Production Time: We move fast, but we move right. Most orders take 2-4 weeks to finish, but if you’re in a rush, just let us know—we’ll make it happen.

Quality Check: Every hat gets a once-over (and then some) to make sure it looks sick, fits great, and will hold up to whatever you throw at it.

Shipped & delivered

Once your hats are ready, we’ll pack ‘em up and ship ‘em out. We’ve got options for shipping, so no matter where you are, your gear’s on the way.

Tracking Info: Keep an eye out for tracking details in your inbox so you can follow your hats right to your doorstep.

Unboxing Day: Pop open that box and check out your new, custom-designed hats in all their glory.

See the Zephyr Difference

Our track record for quality and popularity at retail speak for themselves. Just watch the customer engagement at a Zephyr retail display, and you’ll see why we’re considered as the best headwear provider in the College and Resort space.

When brand alignment, quality, and sales volumes matter, Zephyr delivers.