Constructions of Hat & Cap


Here are the common terms we usually use to describe our hat/cap.
A cap is usually made of following 8 elements. It is important to know all the details before we make the 1st sample for you.


Style
3 panels
- 3 cutting panel on crown. Usually 3 vertical panels.
- Since it requires less fabric, it is commonly used for low cost advertising/promotional purpose.

4 panels
- 4 cutting panel on crown. Usually 4 vertical panels.
- Require a little bit more fabric than 3 panels cap.
- It is not a common style.

5 panels
- 5 cutting panel on crown. 1 panel on front, 1 on each side and 2 at back.
- Better shape than 3 or 4 panels cap.  
- Since printing cannot apply on seam, printed logo on front is very common on this style.

6 panels
- 6 cutting panel on crown. 2 panel on front, 1 on each side, 2 at back.
- it is the most popular style.

x panels
- Multi cutting panel on crown. The number of panels on front, side and back is depends on design.
- Each panel is cut and sewn together to form the desired shape.
- Since it requires more fabric and sewning time, it is relatively more expensive.
- It is usually mixed col. in one cap, which gives a more sophisticated look.

6+X panels
6 cutting panel on crown with extra panel applique on it.
It gives the same effect as x panel from outside. But it has a less cluttered appearance inside of the crown.
The cap itself is heavier compared to x panels caps, as it requires even more fabric.


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Following are common materials we use for caps. For details and pictures, please click here to link to our Materials page.
  • Brushed Cotton Heavy Twill 6838
  • Brushed Cotton Heavy Twill 7444
  • Cotton Heavy Twill 7444
  • Brushed Cotton Twill 9648
  • Brushed Cotton Twill 10856
  • Cotton Twill 10856
  • Brushed Cotton Twill 10858
  • Cotton Twill 10858
  • Pigment dyed Cotton Twill 12860
  • Brushed Polyester/Cotton (T/C) 10858
  • Polyester/Cotton (T/C) 10858
  • Cotton Canvas 7240 (8oz)
  • Cotton Canvas 8431 (10oz)
  • Cotton Canvas 4332 (12oz)
  • Cotton Corduroy 8 wales
  • Cotton Corduroy 11 wales
  • Cotton Corduroy 16 wales
  • Cotton Corduroy 21 wales
  • 380gm Polyester Microfleece
  • 380gm Polyester Polar Fleece
  • 280gm Polyester Polar Fleece
  • Polyester Microfiber 11592
  • Wool Melton (Wool blend)
  • Wool Flannel (Wool blend)
  • 210T Nylon Ripstop
  • Denim
  • Polyester Satin

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Purpose for wash effect is to have rough / torn / old appearance. Not all kind of fabrics can wash with good result. Usually it is depends on the dyeing substance of the fabric when it is dyed.

To achieve different washing effect, we can do fabric wash or garment wash. Bleaching may require to achieve better result.

Fabric wash

  • Wash fabric before cut and sewn.
  • The disadvangtages to have fabric wash are - The consumption of fabric will increase since fabrics might not be washed evenly - Each panel and peak might have colour differences after sewn.

Garment wash

  • Wash cap after all sewing processes.
  • Wash effect is more obvious compared to fabric wash. Tinge might occur on centain dye-stuff.

Washing method:

  • Regular wash or +bleach
  • Stone wash or +bleach
  • Sand wash or +bleach
  • Enzyme wash
  • Pigment wash

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Shape of a cap is depends on which kind of lining/lamination is used.

Fitted / Low Profile

  • Shape of crown is smooth and fitted to the shape of human head. It can be with or without lining.

High Profile

  • The height of the front panel is about 2cm higher than the low profile cap. It must be lined.

Lining (or Lamination)

  • Nylon - its structure gives the cap better shape and flexibility on front panels.
  • Cotton - its structure gives the cap good shape but less flexibility on front panels.
  • Soft Cotton or Woven fabric - its structure gives the cap good shape but no flexibility on front panels at all.
  • Half-moon buckram - it is a Cotton layer in a half-moon shape. It helps with structure shape, usually for a 5 panel cap.

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Following are common adjusters we use for caps. For details and pictures, please click here to link to our Back Closure page.
  • Plastic snap (7 holes for adjustment)
  • Plastic zipper
  • Self fabric strap with metal clip buckle
  • Self fabric strap with metal clip buckle + metal grommet
  • Self fabric strap with metal clip buckle + sewn grommet
  • Self fabric strap with metal snap buckle
  • Self fabric strap with metal snap buckle + metal grommet
  • Self fabric strap with metal snap buckle + sewn grommet
  • Self fabric strap with metal sun buckle
  • Self fabric strap with plastic zipper (7cm or 9cm rail)
  • Self fabric wrapped elastic strap
  • Self fabric covered elastic
  • Short self fabric strap with velcro
  • Long self fabric strap with velcro
  • Long self fabric strap with velcro + sewn grommet

Instead of self fabric strap, Real Leather, Synthetic Leather or Woven Tape are commonly used with velcro straps.

Instead of a plain clip buckle, embossed buckles are also commonly used. But embossment set up charge is required.

Colour of metal buckles are : Brass, Gold, Matt Silver, Silver (Nickel), Matt black.


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Following are different kinds of accessories we use on caps. For details and picture, please click here to link to our Accessories & Trims page.
Top Button
Wrapped by self fabric **This is our standard**
Wrapped by leather Wrapped by synthetic leather
Metal, usually with emboss logo
Eyelet
Sewn **This is our standard**
Metal 5mm (in diameter)
Metal Mesh 10mm (in diameter)
Metal Mesh 12mm (in diameter)
Metal Mesh 14mm (in diameter)
Inner Tapes
Polyester **This is our standard**
Cotton sheeting
Woven tape
Sweatband
Cotton sheeting + foam + PVC **This is our standard**
Self fabric + foam + PVC
Self fabric + foam + PVC with 3 rows stitching
Terry towel + foam + PVC
Peak / Brim
<Shape>
7cm long (from center), usually for 6 panels cap
7.5cm long (from center), usually for 5 panels or multi-panel caps

<Number of stitching>
6 rows for adult
4 rows for youth
2 rows for kids
1 row for baby

<Sandwich>
usually in self fabric, contrast colour.

<Binding>
usually in 8mm wide, constrast colour.
Label
Printed label **This is our standard**
Woven label
Satin label
Stitching
Matching colour double stitching **This is our standard**
Contrast colour double stitching
Transparent double stitching

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Size of a cap is flexible. However, we define our cap according to the following sizes. Each size is based on the plastic snap adjuster with all buttons fastened.
  • Adult/Men : 56-57cm
  • Youth/Ladies : 54-55cm
  • Kids : 51-52cm
  • Baby: 47-48cm (base on elastic strap relax)

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To advertise your company or your brand, you need a logo on the cap. There are several methods we recommended.