Custom Foam Products– Foam Party Hats Inc
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Graterhead gray foam cheese grater hat with oversized holes and handle
Graterhead
Wig with Large Bow - Foam Party Hats Inc
Wig with Large Bow
Graterhead navy blue and orange foam cheese grater hat with oversized holes and handle
Graterhead - Navy Blue/Orange
Turd Ferguson Cowboy Hat - Foam Party Hats Inc
Giant Turd Ferguson Cowboy Hat
Headband Wig - Foam Party Hats Inc
Headband Wig
Party Glasses - Foam Party Hats Inc
Party Glasses

Check out our hats at events all over the country!

Party Glasses - Foam Party Hats Inc
Party Glasses
Foam Sheets - Foam Party Hats Inc
Foam Sheets
Bear Down foam hand navy blue and orange bear claw with Bear Down slogan
Bear Down Foam Hand
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Custom Foam Products

Custom Foam Products

Want Something That Really Stands Out?

We take pride in our commitment to quality, and every foam hat is crafted with top-notch materials, passion, and precision by skilled artisans right here in the USA.

Our Custom Foam Products are tailor-made based on your specifications to ensure you get exactly what you’re looking for.

Let’s Get Started!
Foam FingersFoam Fingers
Foam MasksFoam Masks
Foam CushionsFoam Cushions
Foam TiesFoam Ties
Foam SunglassesFoam Sunglasses
Foam HeadbandsFoam Headbands

What to Expect When Ordering Custom Products:

$$$

Budget Conscious Creations

We’ll work with you and your budget to ensure you get what you’re looking for

100+

Minimum Order Quantity

A minimum of 100 units must be ordered for Custom Products and Designs

2-4 weeks

Expect 2-4 Week Minimum for Delivery

With so many Custom Products to make, we’ll need a little time to make sure they’re awesome!

Let’s Get Started!

Recent Specialty Projects

Duracell's Airbox Hat Took Over Austin

Custom Foam Hats●Formula 1●Event Giveaway

In 2023 Duracell turned the Williams Racing Formula 1 airbox into a giant battery, then asked us to make it wearable. Our custom foam hat was the hit of the Austin Grand Prix, and fans kept asking for it back.

Duracell reordered 1,000 in 2025, and we’ve redesigned it for the 2026 race.

Number of Units1,000+ units

FIFA World Cup 2026: 200,000+ Custom Foam Fingers & Hats

Custom Foam Fingers●Custom Foam Hats●Licensed Foam Products

When the biggest sporting event on the planet came to North America, FIFA needed someone who could turn foam into fan-madness. That someone was us. After a year of pitches and approvals, we earned the official FIFA World Cup 2026 license — and put our custom foam fingers and foam hats on shelves across the US, Mexico and Canada, inside stadiums, and at FIFA Fan Fest.

200,000+ foam products made. $2,000,000+ in revenue. One giant party.

Turnaround Time2025 pitch → 2026 kickoff
Number of Units200,000+ units

Ace Hardware Put a Groundhog on 1,000 Heads

Custom Foam Hats●Event Giveaway●Brand Activation

Ace Hardware — Official Yard Care Sponsor of Groundhog Day, Punxsutawney, Pennsylvania.

Ace asked us to put a groundhog on people's heads. We designed and produced 1,000 custom foam groundhog hats for Groundhog Day at Gobbler's Knob — worn by a crowd out in the February cold before sunrise, waiting on Punxsutawney Phil.

Number of Units1,000 units

LOVE CORN's Foam Corn Hat Went Global

Custom Foam Hats●Brand Activation●Retail Sampling

LOVE CORN wanted a hat as loud as the snack: a giant ear of corn you wear on your head. We have been making them ever since — worn by their teams at sampling events, Topgolf activations and in-store demos across the US and the UK.

5,000+ hats and counting, with a new run ordered every year.

Number of Units5,000+ units and counting

1,500 Giant Charro Hats for Corona's Cinco de Mayo

Oversized Charro Hats●Foam Flower Crowns●Brand Activation

Corona came to us with one rule: make it oversized enough to turn heads. We produced 1,500 giant foam charro hats and 1,000+ foam flower crowns for Cinco de Mayo, worn by brand ambassadors in bars, at retail and at events across the country.

The hats came back for Fiestas Patrias that same year.

Number of Units1,500 charro hats + 1,000 flower crowns

Now Every Bulls Fan Can Be Benny

Custom Foam Mascot Hats●Licensed Retail Product●NBA

The Bulls' retail team had one request: put Benny on people's heads. So we did — horns, snout, grumpy eyebrows and all, built straight from the team's own guidelines. The horns are painted white so they never yellow on the shelf.

1,000 of them shipped with a UPC and a hangtag, ready for the team store.

Number of Units1,000 units

We’ve Also Worked With:

WalmartCVSFIFA World Cup 2026NFLAlbertsonsBurger KingTyson FoodsSpirit HalloweenDuracellWeberAce HardwareLOVE CORNCoronaChicago BullsXPEL

Let’s Get Started!

Our team thrives on creating new Foam creations, and we can’t wait to hear about what you want!

Not sure where to start?
Schedule a call with our team!

Custom Creations in the Wild

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Frequently Asked Questions

What is the minimum order quantity for custom products?

A minimum of 100 units must be ordered for all custom foam products and designs. If you need fewer than 100 hats, browse our ready-to-order catalog where many styles are available in smaller quantities.

How long does it take to receive my custom order?

Custom orders typically take 2–4 weeks from approval to delivery. We recommend reaching out as early as possible before your event date so we have enough time to make sure they're amazing.

What types of custom foam products can you make?

Beyond custom hats, we create a wide range of foam products including foam fingers, foam cushions, foam masks, foam fans, foam ties, foam sunglasses, and foam headbands. If you have a concept in mind that isn't listed, reach out and we'll let you know what's possible.

How does pricing work for custom orders?

We're budget-conscious and will work with you to find a solution that fits your budget. Every custom hat is crafted with top-notch materials, passion, and precision. Fill out the form on this page or schedule a call with our team to get started with a quote.

What information do I need to provide to get started with my Custom Order?

The more details you can give us, the better. When you reach out, let us know what you're envisioning, your event date, your estimated quantity, and any specific colors, logos, or design elements you want included. From there, our team will follow up to walk you through the rest of the process.

We Also Sell Wholesale!

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FPH Wholesale