Baseball Cap Size Chart: Every Measurement in One Place
Most cap sizing questions come down to one number and knowing which chart it belongs on. We keep all of them together.
Measure your head circumference in inches, then read across to the closure type you're ordering — adjustable, fitted or stretch-fit all express the same measurement differently. Adjustable covers roughly 21.5 to 24 inches in one size. Fitted uses hat sizes from 6 3/4 upward. Stretch-fit uses two or three bands. The measurement doesn't change; only the way it's labeled does.
- One measurement, three labeling systems. Adjustable, fitted, stretch-fit.
- Adjustable covers about 21.5–24 in. Most adults in one size.
- Fitted uses hat sizes. 6 3/4 through 8, roughly.
- Made in the USA, no minimums. One hat is a real order.
Adult Size Chart
| Inches | Centimeters | Fitted size | Stretch-fit band | Adjustable |
|---|---|---|---|---|
| 21 1/4 | 54 | 6 3/4 | S/M | Smallest settings |
| 21 5/8 | 55 | 6 7/8 | S/M | Yes |
| 22 | 56 | 7 | S/M | Yes |
| 22 3/8 | 57 | 7 1/8 | S/M – L/XL | Yes |
| 22 3/4 | 58 | 7 1/4 | L/XL | Yes |
| 23 1/8 | 59 | 7 3/8 | L/XL | Yes |
| 23 1/2 | 60 | 7 1/2 | L/XL | Yes |
| 23 7/8 | 61 | 7 5/8 | L/XL – XXL | Largest settings |
| 24 1/4 | 62 | 7 3/4 | XXL | At or beyond the limit |
Fitted sizes advance by an eighth, which is roughly three eighths of an inch of circumference.
Fitted sizing is the only system where the number relates to an actual dimension — it derives from head diameter rather than circumference, which is why the numbers look unrelated to the inches beside them. Our detail is at the adult hat size chart.
If you are between two fitted sizes, size up. A cap slightly loose sits correctly; a tight one presses at the sweatband and cannot be adjusted.
Youth Size Chart
| Size | Inches | Centimeters | Approximate age |
|---|---|---|---|
| Infant | 16–18 1/2 | 41–47 | 0–12 months |
| Toddler | 18 1/2–20 | 47–51 | 1–4 |
| Youth XS | 19–20 | 48–51 | 2–4 |
| Youth small | 20–21 | 51–53 | 4–7 |
| Youth medium | 20 1/2–21 1/2 | 52–55 | 7–10 |
| Youth large | 21 1/2–22 1/2 | 55–57 | 10–14 |
Youth bands overlap deliberately and are not standardized between manufacturers.
Youth large overlaps adult small almost exactly, which is why many children over about eleven are better served by an adult adjustable cap. Our full breakdown is at the youth hat size chart.
How to Measure
- Use a soft tape, or a strip of string or paper measured against a ruler afterward.
- Wrap it around the head about a finger's width above the ears.
- Cross the middle of the forehead, not the hairline and not the brows.
- Keep it level all the way round. A tilted tape reads short.
- Snug rather than tight, and over the hair as it is normally worn.
- Read to the nearest quarter inch and round up if between sizes.
The level point causes most errors. Checking that the back of the tape sits at the same height as the front takes a second and prevents a cap that is a size too small.
Measure over the hair as it is normally worn. Thick, curly or tied-up hair can add enough circumference to change the size, and the hat sits over it rather than under it.
Which System to Order
- Adjustable. One size covers 21.5 to 24 inches. The right choice for any group you cannot measure.
- Fitted. Cleanest silhouette, no adjustment, and every wrong guess is a wasted hat. Suits individual orders and known measurements.
- Stretch-fit. Two or three bands, no visible closure. A middle option, and anyone between bands is poorly served.
- Youth adjustable. Covers a wide age range and grows with the child.
For a group order of any size, adjustable is almost always correct. Our comparison at the Flexfit hat size chart covers stretch-fit sizing specifically.
Fitted sizing varies between manufacturers. Sweatband thickness and crown depth both affect how a labeled size fits, so a 7 1/4 in one brand can differ from another.
What Changes the Fit Beyond the Number
- Hair. The largest variable and the least accounted for. Volume can add a full size of effective circumference.
- Sweatband thickness. A padded band takes up internal circumference, so the same labeled size fits smaller.
- Crown depth. A deeper crown sits further down and feels looser at the same circumference.
- Fabric. Cotton shrinks, particularly in heat. On a fitted cap that changes the size permanently, which is one reason garment-washed blanks are worth specifying.
- Head shape. Round and oval heads of the same circumference fit differently, which adjustable closures absorb and fitted caps do not.
Our note on the hat size conversion chart covers converting between systems, including international sizing.
- A tilted tape. It always reads short and produces a cap too small.
- Sizing down when between sizes. Loose sits correctly; tight cannot be fixed.
- Fitted caps for an unmeasured group. Every wrong guess is a wasted hat.
- Assuming fitted sizes match across brands. Sweatbands and crowns differ.
International Sizing
Caps sold outside the US use different labeling, which matters for anyone ordering from an overseas supplier or shipping abroad.
- European sizing uses head circumference in centimeters directly — a 57 is a 57cm head. It is the clearest system of the three, since the number is the measurement.
- UK fitted sizing uses the same fractional numbers as the US and runs one eighth smaller. A US 7 1/4 is a UK 7 1/8 for the same head.
- Japanese sizing also uses centimeters, generally matching the European convention.
The practical approach is to work in centimeters when dealing with any non-US supplier, since it is unambiguous. Converting through fitted sizes introduces the UK offset and the manufacturer variation at the same time.
For a program ordering domestically and shipping internationally, adjustable caps sidestep the question entirely — there is no size to convert.
Group Ordering
- Default to adjustable unless you have measurements for everyone.
- Add a youth size if the group includes children under about eleven.
- Order ten percent spare for late additions and replacements.
- Stay on one blank model so sizing stays consistent across the order.
- Expect one or two outliers on any roster of thirty, at either end of the range.
Our guide to sizing for group orders covers the planning in full.
When the Chart Does Not Help
Three situations where the measurement is correct and the cap still does not fit, worth knowing before assuming a sizing error.
- Between fitted sizes. Fitted caps advance in eighths, and a head measuring squarely between two has no correct option. Sizing up and using the crown's natural give is the standard answer.
- Outside the adjustable range. Below about 21.5 or above about 24 inches, an adjustable cap runs out. Fitted sizing extends further in both directions, and youth sizing covers the small end.
- Unusual head shape. A markedly round or long head can find a correctly sized cap presses at two points and gapes at two others. Adjustable and stretch-fit both handle this better than fitted.
In each case the fix is a different construction rather than a different size. If someone reports a cap not fitting despite a correct measurement, the closure type is usually where the problem sits.
What We Tell Customers Who Ask
Adjustable and fitted blanks cost similarly. The saving on adjustable is administrative — one size to order, stock and distribute rather than eight.
A cap worn at the extreme of its adjustment stretches the closure every time it goes on. Someone at the largest setting will loosen it over a season, which is worth knowing before assuming a cap has failed.
Specify garment-washed blanks for fitted caps. Most of the shrinkage has already happened, so the size the wearer receives is the size they keep.
For almost any branded program we would run adjustable caps in one adult size, plus a youth adjustable size if children are included. It covers the group, simplifies the order and forgives an estimate.
We size up when a measurement falls between bands, because a loose cap can be adjusted and a tight one cannot. Free digital proof, free artwork setup on twelve or more, no minimums.
The adult hat size chart, the youth hat size chart, the hat size conversion chart.
Frequently Asked Questions
How do I measure my head for a baseball cap?
Wrap a soft tape around your head about a finger's width above the ears, crossing the middle of the forehead, level all the way round and snug rather than tight. Measure over the hair as you normally wear it.
What size does an adjustable cap fit?
Roughly 21.5 to 24 inches of head circumference across seven or eight settings, which covers most adults in a single size.
What fitted size do I need?
Read your circumference against the chart — 22 inches is about a 7, 22 3/4 is about a 7 1/4, and 23 1/2 is about a 7 1/2. Round up if you fall between sizes.
Why don't fitted sizes match the inches?
Fitted sizing derives from head diameter rather than circumference, which is why 7 corresponds to about 22 inches around rather than to any number you measured directly.
Do fitted sizes match across brands?
Not exactly. Sweatband thickness and crown depth both affect how a labeled size fits, so a 7 1/4 in one brand can sit differently from another.
What should I order for a group I cannot measure?
Adjustable caps in one adult size, plus a youth adjustable size if children are included. Expect one or two people on a roster of thirty to sit outside the range.
Is there a minimum order?
No. One hat is a real order, and artwork setup is free on orders of twelve or more.
One measurement, then read across. Order custom baseball caps — start on the quick order page — adjustable, fitted and stretch-fit in every size. Free digital proof before production, free artwork setup on twelve or more, no minimums. Browse custom hats.
Customer favorite: Flexfit 6297F Pro Baseball On Field.
Popular blank: OTTO 5-Panel Baseball. Browse all custom Otto hats.
★★★★★ 4.9/5 · 23,000+ reviews · Made in the USA
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