Caps built from the panel up.

Not on decorated blanks. We will embroider a single cap if that is what you need — the per-unit price is simply higher. Pricing steps down meaningfully at 25, then again at 100.

A fully bespoke build is different: because we are making the cap itself rather than decorating an existing one, the minimum is 100 units per style and colourway.

Decorating a blank means we start with a finished cap in the profile and colour you pick and apply your mark to it. No minimum, 7–14 days, and you control the decoration but not the cap.

Building from scratch means we make the cap to your pattern — panel count, crown height, peak shape, fabric, lining, closure, labels, packaging. It takes 8–12 weeks including a physical sample, and it needs volume behind it. Most first orders are Route A; brands building a label go Route B.

Yes. Thread is matched to a Pantone reference or to a physical sample you send us — an existing cap, a jersey, a swatch. Sublimation and print are matched the same way.

One honest caveat: thread, printed fabric and moulded PVC are three different materials and will never be a perfect match to each other under every light. Where a job mixes methods we will tell you which one to treat as the master.

No, and it is more common than you would think. Send whatever you have — a photo of an old cap, a scan of a letterhead, a screenshot from a website. Our designers redraw it to production quality at no charge and send it back for your approval before anything is stitched.

You keep the redrawn file.

Most adjustable caps are one-size-fits-most, roughly 55–61 cm. Fitted caps come in S/M and L/XL, or true fitted sizing on bespoke builds. Junior caps run about 52–56 cm.

For mixed junior and senior orders we recommend adjustable builds — it removes the sizing round entirely and no one ends up with a cap that does not fit.

Yes. On bespoke builds a physical pre-production sample is part of the process and nothing goes to bulk until you approve it.

On decorated blanks we can send a single decorated cap as a paid sample, credited against your order if you proceed. For embroidery we can also send a stitch-out — the mark sewn onto a fabric swatch — which is faster and cheaper if the question is about the artwork rather than the cap.

Yes. Private-label work is a standard part of what we do. Your woven neck or sweatband label, your printed hangtag, your barcode, individually poly-bagged and packed retail-ready.

There is no Zealots marking on a white-label cap anywhere — not on the sweatband, not on the packaging.

Standard terms are a 50% deposit to lock in production and the 50% balance before dispatch. For incorporated clubs, schools and established companies we offer net-14 invoicing on approved accounts with no deposit required.

Purchase orders are accepted. Ask about split payment if individual members are paying their own share.

Decorated blanks: 48 hours for the mockup, then 7–14 days in production once you approve. Allow around three weeks door to door.

Bespoke builds: 2–3 weeks for the sample, then 6–8 weeks for bulk production and freight. Allow 8–12 weeks and brief us well before the season or launch date.

If you have a hard deadline, tell us at the brief stage rather than after. We can usually work to it — but only if we know about it early.

Every Zealots order is covered by our Fault-Free Guarantee. If a cap arrives with a manufacturing fault — a bad stitch, a misapplied patch, a colour that does not match the approved sample — we replace it free and cover materials, production and freight. Send a photo within 30 days of receipt.

Normal wear after use is not covered. Genuine defects always are.