As an FYI- The current trend in hats is an unstructured, low to mid-profile, sandwich visor with a velcro closure. With any type of clothing, you want to mimic retail as closely as possible-retail sets the trends. We're doing a lot of side and back embroidery, as well as some special touches done offshore such as visor embroidery.
Right now, you should be able to buy the hat described above for about $4.75 @ 144 qty. with up to 10,000 stitches.
And if you're going to give away hats as promotions, try this. Put them in your shop with a price sign in front of them (say $15). When you want to give one to someone, go over, pull one off the shelf and hand it to them. It automatically establishes a value of $15.00 to the gift, whereas just pulling one out of a box does not.