person cutting fabric


Bucket hats have gained popularity in recent years, appealing to both fashion-conscious individuals and outdoor enthusiasts due to their versatile style and practical sun protection. However, not all bucket hats are equal, and selecting the right material can significantly impact comfort, durability, and style. This article will examine essential factors to consider when choosing a material for custom or promotional bucket hats while addressing common questions about this iconic headwear. Whether you aim to promote your brand at corporate events or provide stylish sun protection for your team, selecting the appropriate material is crucial in achieving your goals.


Bucket hats come in a variety of materials, each with its own unique properties. When selecting the right material for your custom bucket hat, it’s important to consider factors such as durability, comfort, and style.

Common Materials for Bucket Hats


image of cotton cloth

Cotton is a popular material for making bucket hats because of its natural plant fiber properties. It’s soft, breathable, sweat-absorbent and comfortable. Cotton comes in various colors and is easy to clean. Although it may not be the most durable option, cotton can be recycled and naturally degrades(Cotton can biodegrade in compost within a week, but typically takes around five months under natural conditions.), making it an environmentally friendly choice. Cotton fibers are commonly utilized in the production of canvas, denim, terry cloth, twill and other fabrics used for bucket hats..


polyester yarn
polyester yarn

Polyester is a synthetic fiber widely used in textiles and apparel. It is derived from polyethylene terephthalate (PET), which results from the reaction between ethylene glycol and terephthalic acid. Polyester fibers can be produced as filaments or short-cut fibers, which are then spun into yarns.

Polyester fabrics have several desirable properties such as durability, heat resistance, and wrinkle resistance. However, they have poor moisture absorption capabilities and may cause discomfort when worn for extended periods. Despite this drawback, polyester fabric remains the most cost-effective material used to make fisherman’s hats; hence it is ideal for projects with limited budgets.

Commonly used fabrics for bucket hats include polyester canvas, polyester twill, and pongee lining made of polyester.

Recycled fabric

Commonly recycled fabrics include recycled cotton, nylon, and rPET. Recycled cotton involves converting cotton fabric into fibers that can be reused in textile products. Cotton can be recovered from pre-consumer (post-industrial) and post-consumer waste. Recycled nylon is made by breaking down nylon waste such as fishing nets and plastic scraps into individual chemical components which are then recombined into sheets of nylon. rPET stands for recycled polyethylene terephthalate, a plastic made from recycled PET plastics commonly used to make packaging and containers for food and beverages. When used to produce fabrics, rPET significantly reduces energy consumption compared to regular polyester fabrics while also preventing discarded plastics from polluting our oceans by giving them new life as useful products.

Joyful Promotions is a company that has been certified by GRS, indicating that the recycled materials used in our rPET products meet global recycling standards. Our commitment to producing sustainable and environmentally friendly goods is reflected in our use of recycled materials, which helps reduce the impact on the;base64,R0lGODlhAQABAAAAACH5BAEKAAEALAAAAAABAAEAAAICTAEAOw==

Pros and Cons of Each Material

Each material has its own advantages and disadvantages, depending on your specific needs.

Tactile SensationWrinkle ResistanceResistance AbrasionBreathablePrice per meter
cotton canvas(8OZ)★★★★★★★★★★★★★★$2.1
polyester canvas(8OZ)★★★★★★★★★★★★★$1.1
cotton twill(240gsm)★★★★★★★★★★★★$2
polyester twill(200gsm)★★★★★★★★★★★★★★$0.8
rPET twill(200gsm)★★★★★★★★★★★★$0.9

Please be aware that the ratings we have provided are a general assessment of these fabrics and may vary depending on factors such as brand, supplier, and color. If you have specific requirements, we can further evaluate these fabrics to determine their characteristics and whether they meet your needs.

Textile post-processing technology can enhance the characteristics of fabrics or address their shortcomings. For instance, cotton canvas can be subjected to water or sand washing processes to achieve a softer texture. Additionally, flame retardant agents may be incorporated during fabric post-processing to improve their resistance to flames.

Factors to Consider When Choosing the Material

When selecting the right material for your custom bucket hat, consider the following factors:

  • Durability: How often will you be wearing the hat, and in what conditions?
  • Comfort: Do you prefer a soft, breathable material, or a more durable, sturdy material?
  • Style: What kind of look are you going for? A classic denim look, or a more rustic, natural look with cotton canvas?
  • Sun protection: Will you be wearing the hat primarily for outdoor activities, and do you need good sun protection?
  • Branding: What kind of branding or customization will you be adding to the hat, and which materials are best suited for your design?


Style options

Downward-sloping brim

The downward-sloping brim bucket hat is specifically designed to shield your face and neck from the sun’s harmful rays. It features a sloping brim that provides better coverage in the front, making it ideal for outdoor activities like hiking, fishing, or gardening where prolonged exposure to sunlight is expected. This type of hat offers excellent protection against UV radiation and helps prevent skin damage on your face, ears, and neck.

Boonie hats

A “Boonie” hat, also referred to as a bush or jungle hat, is a type of headwear made from heavy-duty cotton or other durable materials. It features a wide brim that provides protection against the sun and rain. Boonie hats are popular among military personnel and outdoor enthusiasts due to their practicality and durability. They often come with chin straps for secure fitting in windy conditions and camouflage patterns to blend in with natural surroundings.

Considerations for the occasion

Sporting events: If you’ll be wearing your bucket hat to a sporting event, consider choosing one in your team’s colors to show your support.

Outdoor adventures: For outdoor activities like hiking or camping, look for bucket hats that are made from durable materials like canvas or polyester.

Corporate events: If you’re wearing a bucket hat to a corporate event, consider choosing a style that’s more subtle and professional-looking.

Matching the bucket hat with your outfit


If the promotion is for a specific company brand, competition, or event, it’s important to choose a hat color that matches the main color of the brand. This will help enhance brand recognition. Additionally, selecting a hat color that matches the theme of the activity or tournament can improve participants’ sense of belonging and contribute to an overall positive atmosphere at the event.

Joyful Promotions offers a range of stock colors for bucket hat fabrics that are tailored to match the theme colors of various competitions and events.

color sample catalog of 200gsm twill polyester


When selecting materials for promotional fisherman’s caps, common options include cotton, polyester, recycled PET fiber (rPET), and other materials. Cotton is a natural material that is soft, comfortable, breathable, and skin-friendly. It is also easy to print on and the colors are long-lasting without fading. Therefore, if you want a more comfortable and environmentally friendly option suitable for daily wear, choose cotton material.

Polyester is a synthetic material that is durable, wrinkle-resistant, easy to dry and relatively inexpensive making it suitable for mass production. If you need durability and economy of scale in your fisherman’s cap production process then polyester may be the best choice.

rPET fibers are made by recycling waste plastic bottles which makes them an eco-friendly option with sustainable characteristics. If promoting environmental protection or meeting sustainability requirements are important factors in your decision-making process then rPET may be the most appropriate choice.

When choosing materials for promotional fisherman’s caps consider specific needs as well as budget constraints while weighing the advantages and disadvantages of each option before deciding on the most suitable one.

Fit Size

Make sure your bucket hat fits your head comfortably and isn’t too tight or loose. A well-fitted bucket hat will look more stylish and feel more comfortable to wear.

Promotional fisherman hats typically come in a universal size that fits most adults. However, it’s important to note that various brands and manufacturers may have slightly different sizing standards. To ensure the best fit, we recommend carefully reviewing the product description or size chart before making your purchase.

For those who require a more precise fit, measuring your head circumference is recommended. Simply use a tape measure around the widest part of your head (typically above your eyebrows and ears), then compare the measurement with the product description or size chart to determine which size will work best for you.

image of bucket hat template


Customizing your bucket hat can help you stand out from the crowd and get your brand noticed. Here are some customization options to consider:

Printing Options

  1. Screen Printing: Screen printing is a cost-effective way to add your logo or design to a large number of hats. It involves using a stencil to apply ink onto the surface of the hat. Screen printing is best for simple designs and logos.
  2. Embroidery: Embroidery is a classic option for customizing hats. It involves stitching your design or logo onto the hat using a needle and thread. Embroidery can accommodate more intricate designs and adds a professional touch to the hat.
  3. Heat Transfer Printing: Heat transfer printing involves transferring a design or logo onto the hat using heat and pressure. This method allows for full-color designs and can produce a high-quality finish.

Design Considerations

  1. Company Logo and Brand Image: Custom bucket hats can be a great way to promote your brand. Consider adding your company logo and using colors that reflect your brand image.
  2. Cost-effective Options: If you’re on a tight budget, consider simple designs and fewer colors. Screen printing is the most cost-effective option.
  3. Practicality Considerations: Consider the use of the hat when designing it. If it’s for outdoor activities, consider using materials that provide sun protection or have moisture-wicking properties.


Bucket hats have become a popular choice of headwear for various occasions. When selecting the appropriate material for your bucket hat, it is essential to consider factors such as the occasion, desired level of sun protection and expected style. Common materials used in making bucket hats include cotton, polyester, denim and canvas; each has its own advantages and disadvantages. Customization options like screen printing, embroidery and heat transfer can also help promote your brand or create a unique look for your bucket hat. By considering all these factors, you can create a practical yet stylish bucket hat that meets your needs.

In conclusion, whether wearing a bucket hat for fashion or function purposes, it is crucial to choose the right material and style that suits your needs. Therefore start creating your customized bucket hat today and get ready to stand out!

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