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Manufacturing Process

Fabrics

Most fabrics used for caps are made 100% cotton. A twill construction is most commonly used and the fabrics are coming in a great variety of constructions.

However, polyester, acrylic, wool as well as mixes of these yarns are also used. All fabrics have been re-active dyed to avoid color bleeding.

Cutting of Fabrics

Most fabrics used for caps are made 100% cotton. A twill construction is most commonly used and the fabrics are coming in a great variety of constructions.

However, polyester, acrylic, wool as well as mixes of these yarns are also used. All fabrics have been re-active dyed to avoid color bleeding.

Caps Decoration

Decoration of hats and caps, being embroidery, printing or badges should take place before the hat is fully constructed.

For embroidery, we used new Tajima embroidery machines, for printing is silk screen printing using imported inks and badges are made by factories using Taiwanese technology and equipment.

Assembling the Caps

The decorated panels will be passed to the sewing lines for stitching the panels and peak together and generally assemble the hat with sweatband, strap/closing, top button and sewn-on labels.

There are a great variety of closings to choose from, like velcro, plastic snaps, zippers and metal buckles.

Quality Control (QC)

The hat are passed to the finishing section where the loose sewing threads will be cut off and the quality control section will inspect the finished products.

Upon completion, the hats will be shaped by using a hot mould then packed.

Hats Terminology

7 Terms you must know before producing a cap

Crown

The front part of the hat fits over the top of your head and touches your forehead. Usually the main area of embroidery and customization on caps. Can be created as low profile, medium profile or high profile by adjusting the angle of the front crown.

Low profile slants backward versus high profile that angles almost straight up the front crown. The crown of the cap is also what determines if the hat is structured or unstructured. Structured hats have a buckram fused to the inside of the cap to keep the front ridged.Unstructured caps has no re-enforcement and cap material sits loose against the head.

Top Button

Fabric covered button that sits directly on the top center of the hat at the intersection of the fabric panels. Button color can match the material of the cap or in a contrasting color.

Eyelets

Round holes sewn in the hat for increased ventilation and style. Eyelets can have sewn borders or metal grommets.

Panels

Fabric pieces used to create the shape of the cap. Most are 6 panels caps with a seam in the center of the front crown but there are also 5 panels and 8 panels caps. 5 panels caps are mainly used for the trucker caps or caps that have screen printing on the front instead of embroidery.

Panels are sewn together with thread matching the color of the cap material or made thicker if needed. Other fabric types are wool, mesh or performance materials that allow for greater moisture wicking or ventilation.

Bill or Brim

The visor that extends out from the crown of the cap to shade you from the sun or elements. The bill is normally curved or can be flat as in pro-style caps. Bill is plastic and sandwiched between two pieces of fabric. A contrasting sandwich is created by adding a third piece of fabric along the front of the bill between the top and the bottom fabric. Sandwich fabric is normally in a contrasting color and can be screen printed with text for customization.

Flip style bill is when a contrasting color of fabric is used on the bottom of the bill and is folded up over just the front of the bill to look similar to a sandwich style bill. Stitching on the bill can range from 4 rows to 8 rows. Length of bill varies between styles.

Back Closure

On adjustable caps, there are a variety of closures used. Most popular are velcro, sliding buckle, deluxe locking brass buckle or plastic snap (used on trucker caps most often).

Fitted style and Flex style hats have n closure style on the back nor do they have the hole in the back.

Sweatband

Fabric used on the inside edge of the cap to help absorb sweat and keep your cap looking clean and dry. Sweatband styles range from standard cotton to high performance synthetic material with advanced moisture wicking properties.

Hat Parts

Hat Profile

Low Profile

Low profile is the least steep slant to the front of the hat and this profile is normally associated with a sport or a golf style hat.

Medium Profile

Mid-profile is a bit steeper slant to the front of the hat and is normally associated with what a baseball player would wear.Additionally, this style hat tends to be a bit of deeper fit.

High Profile

High profile is almost a straight up slant to the front of the hat and is normally associated with a trucker or a snapback style hat.

High Profile 5 Panels

5 panels caps are mainly used for trucker caps or caps that have screen printing or large embroidered/printed patch on the front instead of embroidery.

Military Cap

Military cap or forage cap is characterized by a small brim and a tubular construction with a flat top.

Visor

A partial brim, usually extending out at the front of a headband.

Hat Profile

Velcro Strap Closure

Closure composed of 2 strips of fabric with velcro system to adjust the size of the cap.

Plastic Strap Closure

Closure composed of 2 strips of plastic with perforations and slots to adjust the size of the cap.

Fabric or Leather and Metal Closure

Closure composed of a metal clip and a way which fits in the fabric to adjust the size of the cap.The metal clip can be customized and made in a variety of material.

Plain Closure

The back panels of the cap are totally closed and the size is not adjustable.

Hat Closure

Sizing Chart

Size Standard

The following industry standard sizes for cap hats are available:

  • Adult: 56-57 cm (full closure)
  • Youth: 54-55 cm (full closure)
  • Kids: 51-52 cm (full closure)
  • Toddler: 48-49 cm (full closure)
Flex Cap Size Standard

Flex caps measuring hat sizes the way they do for fitted hats. Except rather than having a single size, they have multiple beacause they can stretch.The size of your cap can be adapted to your own specifications.

Hat SIzing

Fabrics

Fabric with spandex

We offer a wide range of fabric mixed with spandex: cotton twill, acrylic, polyester… and elastic sweatband.

Camo

We offer a wide range of camo patterns and colors. We can even print your own pattern.

Custom Patterns

We can print your own pattern. We have full sublimation and all-over printing capabilities.

Fabric Sourcing

For minimum orders we kindly ask that you choose from our wide selection of available fabrics. On the other hand, we can source nearly any fabric in the open market; a higher MOQ may be required.

Do you already have fabric resources you would like us to use?

No problem! Please just send us your fabric to our facilities.

Custom caps for your brand or business with 100pcs minimum order