Branded bucket hats with your company logo

The six-panel is the classic one and fits the head best. The five-panel has a seamless front, which is better for a large embroidery.

Embroidery, almost always. On cotton twill it survives washing, doesn't crack and adds volume. Screen printing only makes sense on technical polyester caps, where the needle would mark the fabric.

Because it lacks the front reinforcement, the buckram, which is what keeps the cap standing upright. Without it, the embroidery pulls it inward within a month.

A metal buckle is the most understated and the one that ages best. Velcro is the cheapest and the worst. Elastic doesn't adjust and only works on children's caps.

Yes, but adjustable: one-size without an adjustable closure leaves a lot of people out. Always check the closure.