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How the cap is made

How the cap is made

Caps are hats that combine a sporty impression with functionality, and are an essential item in casual fashion. There are many different styles of caps, including baseball caps, but the basic manufacturing process is the same for all caps. Here we will explain in detail how caps are made .

1. Design and pattern making

The first step in making a cap is deciding on the design .

  • Crown height and silhouette

  • Brim curve and length

  • Number of panels (usually 5 or 6)

  • Adjuster (size adjustment part) specifications

After deciding on these points, a pattern is created. The shape of the crown changes significantly depending on how the panels are combined, so the shapes of the panels are adjusted to fit the design intent.

2. Fabric selection and cutting

The choice of fabric is an important factor in determining the impression of a cap.
Typical fabrics include:

  • Cotton twill (breathable and casual)

  • Nylon or polyester (suitable for sports, water repellent)

  • Wool blend (warm material for autumn and winter)

  • Leather and denim (unique and durable)

And more.

Once the fabric is selected, the panels, brims, sweatbands, and other parts are cut according to a pattern. For mass production, precise shapes are cut using an automatic cutting machine , but for high-end caps, each piece may be cut by hand.

3. Sewing the panels – making the crown

The crown of the cap (the part around the head) is made by sewing multiple panels together to create a three-dimensional shape .

For 6 panel caps (most common style):

  • Six symmetrical panels are sewn together to create a beautiful dome-shaped crown.

  • Stitching is added to the seams to increase strength and add an accent to the design.

  • Eyelets (small holes) may be drilled to ensure ventilation.

During this process, great care is taken to ensure that the crown is shaped properly and that no distortion occurs in the stitching .

4. Brim Forming and Sewing

Another important part of a cap is the brim.

The brim has

  • Flat brim

  • Curved brim

There are two types:

The inside of the brim is lined with plastic core or cardboard to give it the right amount of stiffness, then the core is wrapped in fabric and the edges of the brim are stitched to help keep the shape.

5. Crown and brim connection

Once the crown and brim are completed, the two pieces are sewn together to form the cap .

At this time, the brim angle and joints are carefully adjusted to ensure there is no distortion. In particular, sports caps often have double stitching to increase strength .

6. Attaching the sweatband

Attach a sweatband to the inside of the cap.

  • Cotton tape (breathable and soft to the touch)

  • Mesh material (highly sweat-absorbent and quick-drying)

Various materials are used depending on the application.

This part prevents sweat from soaking directly into the fabric of the cap, keeping the cap comfortable to wear.

7. Installing the back adjuster (adjustment function)

A back adjuster is attached to adjust the size of the cap.

There are different types of adjusters:

  • Snapback (plastic button closure)

  • Strapback (leather or nylon strap adjustment)

  • Velcro (magic tape)

  • Fitted cap (made of rubber or elastic material for a snug fit)

The finish of this part will determine the comfort of the cap and the individuality of its design .

8. Embroidery, patch and print processing (decoration)

This is the process of adding a brand logo or design to the front, sides, and back of the cap.

Main processing methods:

  • Embroidery (three-dimensional, luxurious finish)

  • Patches (for a classic look)

  • Screen printing (allows flat designs like T-shirts)

  • Laser cutting and patching (for unique customization)

This process can be used to create not only simply designed caps, but also original caps with company logos and uniform caps for sports teams, all with a unique finish.

9. Finishing touches and final checks

Once all the parts are assembled, a final check is performed.

  • Is there any loose stitching?

  • Does the size adjustment function work properly?

  • Is the design misaligned?

  • Is the brim securely fastened?

We check every detail, such as the above, and if there are no problems, we begin preparation for shipment.

The cap is an item packed with craftsmanship and functionality.

Although the cap appears to have a simple design, it is an item packed with fine craftsmanship , such as the panel structure, brim angle, fabric selection, and decoration .

Because caps are used in a wide range of situations, including sports, street, fashion, and outdoors, both functionality and design are emphasized, making use of the skills of milliners.

When you put on a cap, be sure to take a look at the fine details and background !

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