Flexfit is not a generic cap style. The name refers to a proprietary elastic sweatband developed by Yupoong that stretches to fit the head without a snapback, strapback, or any other closure adjuster. That elastic band is what defines every Flexfit cap: the back panel has no hardware, no snap, no buckle, and no strap. The result is a clean, uninterrupted rear surface that can be fully decorated with embroidery or heat transfer, which is not possible on caps with a plastic snap adjuster sitting in the center of the back panel.

Because the stretch sweatband replaces the adjustable closure, Flexfit caps do not come in one-size-fits-all. They come in S/M and L/XL. This is the most critical ordering detail for wholesale buyers: every color in a Flexfit program requires two separate SKUs. If you are pricing a run of 144 caps in one color, you are ordering some quantity of S/M and some quantity of L/XL. Most programs split 60/40 or 50/50 depending on the end-customer. Factor this into your size distribution planning before pricing the job.

Flexfit 6277 Structured Twill: The Standard for Puff Embroidery

The Flexfit 6277 is the most specified Flexfit style in wholesale embroidery programs. The front two panels are backed with buckram, which holds the panel rigid during stitching and prevents needle pull-down on high-stitch-count designs. The structured buckram front is what makes the 6277 compatible with 3D puff embroidery, which requires a stable, non-yielding surface to hold the foam insert in position under the needle. Flat designs at 8,000 to 12,000 stitches register cleanly on the 6277 front panel without puckering or misalignment.

One setup detail specific to Flexfit stretch caps: the stretch fabric requires a slightly different cap frame tension than a rigid woven snapback. The elastic sweatband adds lateral resistance when the cap is loaded into the frame. Set frame tension on a sample before the production run. Over-tensioning a Flexfit cap distorts the crown profile and causes the design to appear compressed after the cap relaxes off the frame. This is a common setup error when shops switch from snapback programs to fitted Flexfit programs.

Flexfit 110 Trucker: Mesh Back with the Same Stretch Fit

The Flexfit 110 is the trucker variant with a structured foam-front panel and mesh back panels. It carries the same proprietary elastic sweatband as the 6277, so it also comes in S/M and L/XL rather than OSFA. The foam front panel on the 110 holds flat embroidery and heat transfers well. Puff embroidery is not recommended on the foam front because the foam substrate is not rigid enough to maintain the profile of the foam insert during stitching. For trucker-style caps with full puff embroidery programs, the structured woven front of the 6277 is the correct substrate. Browse wholesale Yupoong hats for additional trucker and fitted styles from the parent brand.

Ordering Flexfit Hats Wholesale: Size Distribution and Case Pricing

Flexfit caps are available at wholesale case pricing with bulk discounts that increase with quantity. No minimum order is required on any Flexfit style. Because fitted caps require S/M and L/XL as separate SKUs, most decorators ordering 72 or more units per color split the order across both sizes rather than buying a single size. Confirm the S/M to L/XL split with your end-customer before placing the order to avoid imbalanced stock. For broader wholesale headwear across all styles and brands, see the full hats collection. All stocked Flexfit colors ship with fast US delivery from domestic warehouses.