The Sunday Cool Screen Printing Process: Start to Finish

Water based ink is the point between here and heaven. Paired with our Super Soft Tees, the nonexistent feel of our Water based ink is magical and sure to be the talk of the town with you and your group.

Here at Sunday Cool, we inventory 66 different ink colors! These colors were curated based off of customer popularity and diversity. You can view those stock ink colors below.

During the ordering process, you can reference this page to view all of our stocked ink colors. You’ll also be served up a choice of our stock inks when you submit your Art Request Form.

But what if none of the Sunday Cool Stock Inks match my design or logo? Nothing to fear! We can Pantone Match your ink to whatever code you’re needing to a 90% accuracy. 

There are a few requirements to qualify for a Pantone Match on your project:

• Stick to our Super Soft Signature line of apparel.
• The garment color you choose must discharge vibrantly, not vintage. If you need help determining which of our inventory items discharge at which rates, check out our blog post entitled Waterbased Print Results.
• Your order must include 144 units or more. 

Additionally, we charge $25/match! This means if we need to match 2 ink colors to a specific code, it’ll be a $50 charge.

But how do I know which code to send you? Great question! Your organization might have a branding guide including all relevant codes and colors that set your group apart. OR you could send in your logo and ask us! Our talented Art Staff can color match the logo and tell you the code! We work often in the Pantone and HEX libraries!

As always, if you have any questions regarding our inks & matching guides, please reach out to a Sunday Cool Concierge member using the dot icon in the corner of your screen.

‍Everything you need to know before placing an order

Custom foam trucker hats are one of the most versatile, affordable, and memorable pieces of group apparel out there. Whether you're gearing up for summer camp, planning a conference giveaway, or refreshing your church's merch table, a well-designed hat can tie everything together — without breaking your budget.

But before you hit "Get A Quote," let’s break down what makes a great custom foam trucker hat, what to look for in a print partner, and why these foam-front classics are trending hard right now.

Why Choose Foam Trucker Hats?

Custom hats are everywhere. But foam trucker hats? They're in a league of their own — and for good reason.

• They’re lightweight and breathable, making them ideal for hot climates, long events, and high-energy environments like summer camps or youth group retreats.
• They have high visibility — literally and figuratively. A bold print on a foam front panel makes your design stand out in photos, on stage, or across the rec field.
• They’re cost-effective. Compared to embroidery-heavy or premium headwear, foam truckers are easier on your budget.
• They’re just plain fun. Custom foam trucker hats instantly add personality to your group, team, or brand.

What to Consider Before Ordering Custom Foam Trucker Hats

Before submitting your design, here are a few things to think through to make sure your order checks all the right boxes:

1. What’s the goal?

Are you ordering hats for a staff team? Volunteers? Conference giveaways? A mission trip?
Foam trucker hats work great for events where you want something eye-catching, useful, and easy to pack or distribute.

2. How many do you need?

Whether you're ordering a dozen for your youth leaders or a few hundred for an event, our 72-hour turnaround makes it easy to get what you need, fast. Foam truckers are especially great for bulk orders.

3. Do you already have a design?

Our most popular option is to print directly onto the foam front using full-color Digital Ink. That means more flexibility for your design and more vibrancy in the final product. Embroidery and custom patches are available to order as well.

Not sure what to print? Our team of world class artists can help turn your theme or logo into a high-impact hat graphic.

4. What’s your timeline and budget?

At Sunday Cool, our foam trucker hats ship out within 72 hours after artwork approval. No rush fees. No guesswork. Just a lickity-split turnaround.

How Sunday Cool Does Foam Trucker Hats Differently

Not all custom hats are created equal. Here's why Sunday Cool's foam trucker hats are trusted by hundreds of camps and churches.

• Full-color printing with Digital Ink — your design prints crisp & vibrant.
• Low minimums — order a few, or a few hundred*
• Soft foam front with mesh backing — comfortable, breathable, and made to wear again
• Printed in-house by real humans — not robots or drop shippers!!

We’ve printed thousands of these for churches, ministries, and events that wanted something a little more fun, a little more memorable, and a lot more wearable.

*orders start as low as 12 pcs

FAQs About Custom Foam Trucker Hats

How much do foam trucker hats cost?
Pricing depends on your quantity, but foam truckers are one of our most budget-friendly high-value promo options. Click HERE to Get a Quote today.

What kind of file do I need to upload?
A high-resolution PNG or AI file works best. But if you’re not sure, our team will check your artwork and make it print-ready.

Can I see a proof before printing?
Always. We’ll send you a digital mock-up to review and approve before anything goes to print.

What if I don’t have a design?
No problem. Just give us a theme, idea, or logo and we’ll help you create something that looks great on a foam front.

Ready to Design Your Custom Foam Trucker Hats?

When you're working with tight timelines, limited budgets, and high expectations — you need a hat partner who gets it.

At Sunday Cool, we combine fast turnaround, remarkable customer service, and those signature specialty ink prints to bring your ideas to life — on t-shirts and trucker hats alike.

Start Your Hat Order Today

You’ve got a powerful message. A missions team with purpose. And a trip that will stick with people long after the plane lands.

So why settle for mission trip t-shirts that feel... forgettable?

At Sunday Cool, we believe mission trip gear should mean something. It’s more than a shirt or a hat—it’s about creating a wearable reminder of every moment, every connection, and every step of the journey.

Here’s how we help you make that happen:

What Makes a Great Mission Trip T-Shirt?

1. Custom Designs That Actually Inspire

We’ve already done the hard part.
Our team of world class artists have created a full library of mission-themed templates, ready for you to customize with ministry-ready and message-driven designs.

Want something totally custom? Our artists can bring your vision to life from scratch, too!

2. Super-Soft Tees You’ll Actually Wear Again

Our shirts are known for one thing above all: softness.
Printed on our Signature Super-Soft Tee with breathable, water-based ink, your team gets gear they’ll want to live in—whether they’re painting walls or leading worship.

3. Specialty Inks

• Water Reveal Ink – Designs appear when wet
• Sun Reveal Ink – Graphics that show up in sunlight
• Puff Ink – For a dimensional, raised effect

These small touches make a big impact—and turn your shirt into a conversation starter.

4. Fast Turnaround. No Stress.

Need them quick? We’ve got you.
Once you approve your design, your order ships within 72 hours after art approval. What most printers offer as a rush, we offer as our standard!

When to Use Custom Mission Trip T-Shirts

Mission trip tees aren’t just for the trip itself. Here’s how groups use them:

• Pre-Trip Send-Offs – Help your team feel unified and excited
• During Travel – Makes it easier to keep track of everyone (and easier to spot in airport security)
• In the Field – Comfortable and practical for serving
• Post-Trip Gifts – A wearable reminder of what God did through your team
• Supporter Thank-Yous – Gift them to donors or prayer partners

FAQ: Mission Trip Shirts

Do I have to use a template?
Nope! You’re welcome to start from scratch or mix and match design elements. Just send us your idea, and we’ll take it from there.

Can we use our trip verse or location?
Absolutely. Every design is fully customizable—so you can add your destination, year, verse, or even your team members’ names if you want to get fancy.

Do you offer hats or other items too?
Yes. Foam trucker hats, woothoops, stickers, note jotters—you name it. If you want to take your mission trip merch to the next level, we’ll build a package that fits your needs.

What shirt colors work best?
Our most popular mission trip tees are in earth tones or heather brights (like Heather Sky or Heather Mint Julep), but you can choose from dozens of colors. We’ll help guide you based on your design and vibe.

Gear That Speaks Louder Than Words

Mission trips aren’t just a moment—they’re a movement. And your T-shirts should reflect that.

When you print with Sunday Cool, you’re not just getting great design or soft tees (though you are getting both). You’re getting gear that reflects the heart behind the mission.

Ready to create custom gear that speaks louder than words?
CLICK HERE to get started!