Hats are a fantastic add-on item for screen printers. They’re one-size-fits-most, lower-cost, and have fewer sizing headaches than shirts. But screen printing directly on hats is a whole different challenge. Instead of fighting foam fronts and tricky platens, try this: print your design onto hot peel plastisol transfers, then press it onto hats with a hat heat press.
WHY HATS? WHY TRANSFERS?
Hats are affordable, high-margin products that customers love. But direct printing on them requires specialized gear and experience. One-color plastisol transfers let you:
- Print designs in batches with your regular screen printing setup
- Apply transfers on demand using a hat press
- Get consistent, professional results with minimal cost
If you’re looking to expand into headwear without upgrading equipment, this method is the move.
WHAT YOU NEED TO MAKE HAT TRANSFERS
- Transal Premium Hot Peel Transfer Paper
- Transfer Adhesion Powder
- Wilflex Epic Quick White Plastisol Ink
- 158 White Mesh Screen (or 125 mesh for heavier ink)
- Hotronix 360 IQ Hat Press
- Black Nitrile Gloves
- Eye protection
- Mask
STEP 1: SET UP YOUR SCREEN
Reverse your artwork before exposing your screen. You can flip the design in your art file, flip the film before exposure, or reverse it digitally if you're using a CTS system. Since you're printing on paper, not fabric, you don’t need to pre-shrink the transfer paper or use a vacuum platen.
Use a 158 mesh screen for good opacity and edge sharpness. If your transfers feel too thin, go lower to 125 mesh or even 110 mesh to lay down more ink.
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STEP 2: PRINT THE TRANSFER
Load your transfer paper flat and square onto the platen. A small amount of spray adhesive helps keep it in place. Lower your screen and flood the stencil. Use a slow, even stroke with medium pressure to get solid ink coverage and a clean edge.
The goal is to lay down a smooth ink deposit onto the paper. If your screen mesh is too high, you may not get enough coverage. Adjust as needed for visibility and opacity.
STEP 3: ADD ADHESION POWDER
With the ink still wet, dust on your transfer adhesion powder. Be sure to wear gloves to avoid smearing your print. Cover the ink completely, then shake off the excess. This step ensures a smooth transfer when pressed.
STEP 4: GEL CURE THE TRANSFER
Cure the print in a conveyor or with a flash dryer at 260 to 280°F. Use a temp gauge for consistency. You’re aiming for a gel cure, not fully cured, so the ink still adheres when pressed. Test peel the edge. If it pulls clean, you're good. If it smears, it's undercured. If it cracks or resists, it's overcured.
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STEP 5: APPLY THE TRANSFER TO A HAT
Use a Hotronix 360 IQ Hat Press or another hat-compatible heat press. Set it to 320°F, medium pressure, for 10 seconds. Center your transfer, press, and peel while hot. That’s it. Your hat is done and ready to sell.
STEP 6: SCALE IT UP
This process is perfect for bulk production. One sheet of transfer paper can hold 20 or more designs. With only pennies in ink and materials, your margins stay high, and your output stays fast.
RELATED: Step-by-Step Guide to Screen Printing Multi-Color Plastisol Heat Transfers
WHY THIS METHOD WORKS
You don’t need fancy hat platens or foam jigs. Just a screen, plastisol ink, adhesion powder, and heat. The process is repeatable, scalable, and beginner-friendly. It’s ideal for print shops looking to grow without investing in new equipment.
POWER YOUR PRINT
Start creating your own custom hat transfers today with Ryonet’s pro-grade tools and supplies. The process is fast, efficient, and incredibly rewarding.
Shop All Heat Press Transfer Supplies now and keep #poweringtheprint.