Key Facts
- Full brim shell — shields against sun, rain, snow, and dust
- Six-point suspension system — spreads the load across the head
- Evolution Wheel Ratchet — dials in a firm, comfortable fit
- 3D Adjustment harness depth settings — tunes helmet fit precisely
- Meets ANSI/ISEA Z89.1-2009 Type 1 Class E — including reverse donning and lower temperature
- Packed ready-to-wear — no assembly required before use
Description
The Evolution™ 6161 is a full-brim hard hat built on a high-density polyethylene shell. The brim runs the full circumference to shield the face and neck from sun exposure, rain, snow, and dust, while the shell itself meets ANSI/ISEA Z89.1-2009 Type 1, Class E requirements, including the ANSI requirement for reverse donning and lower temperature.
Inside, a six-point suspension system spreads the load across the head, and the Evolution Wheel Ratchet tightens to a firm, comfortable fit. Unique 3D Adjustment harness depth settings let the wearer tune the helmet fit precisely. Universal slots accept various accessories, and the hat arrives packed ready-to-wear with no assembly required.
Your artwork is pad printed onto the shell in a thin, flat layer of opaque spot-color ink that sits nearly flush with crisp edges — a process suited to fine lines and small text on a curved surface.
Specifications
| Brand | Starline |
|---|---|
| Material | High-density polyethylene (HDPE) shell |
| Dimensions | 11 in. depth x 8.75 in. width x 6.5 in. height |
| Weight | 1.2 lb. |
| Origin | Made in the United Kingdom |
Decoration & Imprint
1 method
Your artwork is pad printed onto the hard hat. Pad print lays down a thin, flat layer of opaque spot-color ink that conforms to curved and recessed surfaces, sitting nearly flush with crisp edges — best for fine lines, small text, and tightly detailed artwork.
Pad Print1 color/location included · one-time setup $60.00 · Up to 2 colors
Pad printing (tampography) transfers ink from a silicone pad onto the item, flexing into curves, angles, and recessed areas flat application can't follow. The result is a thin, nearly flush ink layer with well-defined edges — each color prints as an opaque spot-ink solid, holding evenly on contoured or darker surfaces; cured ink resists everyday wear.
Production & Delivery
3 business days production
- Free digital proof — within 24 hours. After we receive your artwork, we will e-mail you the proof. Production time begins after your approval. We allow up to two proof edits at no additional charge.
- Production: 3 business days after proof approval. Production time is for the default single-location, one-color imprint. It may increase for multiple imprint locations, additional colors, and large product quantities. Add 24 hours for your free digital proof.
- FedEx Shipping: Transit time depends on the shipping option and destination. Enter your ZIP code below for estimated arrival dates and shipping prices.
Arrival dates are shown at checkout.
Questions & Answers
Ask about sizing, imprinting or turnaround
- What is the minimum order quantity?
- The minimum order is 20 pieces with Pad Print.
- How much does it cost per unit?
- Pricing falls with quantity: 20–49 pieces $48.20 each, 50–99 pieces $46.54 each, 100–249 pieces $44.99 each, 250–5,000 pieces $42.85 each. Prices are per unit, imprint included — one-time setup charged separately.
- Is there a setup charge?
- Yes — a one-time setup charge of $60.00 per order. The imprint itself is included in the unit price.
- How long does production take?
- Production takes 3 business days after proof approval; a free digital proof is e-mailed within 24 hours of receiving artwork.
- How is it decorated?
- Pad Print (1 color/location included · one-time setup $60.00 · Up to 2 colors).
From our decoration and product guides
- What is pad printing and what does it look like?
- Pad printing (tampography) transfers ink from a silicone pad onto the item, so the pad flexes into curves, angles and recessed areas that a flat application cannot follow. The result is a thin, nearly flush ink layer with well-defined edges. Each color prints as an opaque spot-ink solid that holds evenly on contoured or darker surfaces, and the cured ink resists everyday wear. More about Pad Printed →
- When should I choose pad printing over screen printing?
- When the artwork has fine lines, small text or tight detail that must stay sharp on a contoured or uneven surface, such as a pen barrel or a curved drinkware wall. The conforming pad holds crisp edges where flat methods cannot reach. Pad printing suits fine detail better than flooding large areas, so for broad solid fills, photographs or gradients look at screen printing or a full-color process instead. More about Pad Printed →
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SKU: SAE0001755IN STOCK
SKU: SAE0001755
Evolution™ 6161 Full Brim Hard Hat
Starting At$42.85each, imprint included — one-time setup charged separately
Suited to safety training, wellness programs, employee care kits, and health fairs.
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Questions about uploading artwork? Or pricing, options, process, or anything else? Use the live chat on the lower right of this page, or call us at 1 (844) 667-7666 during office hours to speak to a friendly, helpful professional. Promotion Pros is a family-owned business in West Bend, WI with a decades-long history supporting businesses locally, regionally, and nationwide. You'll always get a helpful professional if you reach out for support — never a robot!