Our clients often ask us to tell them about the components that make a cap, so we have created this guide to explain the different parts of a Baseball Cap.
Panels / Crown
The main body of a baseball cap (called the Crown) is made by sewing 6 triangular panels together, forming the shape of a hemisphere. The panels are constructed to give the cap a circumference of 59cm (for Western markets), or 57cm (for Eastern markets). The closure at the back of the cap normally allows for a 3-4cm adjustment to make the cap either larger or smaller. Using rough numbers, the width of the base of each panel is 10cm, with the length of each side of the panel being around 15cm. Each panel has a small opening near the top, called an Eyelet, which provides ventilation. Sometimes the side panels and back panels are made of mesh to provide the wearer with even more ventilation. The most popular cap of this style is the Trucker cap. The two back panels are the most complex. Each of these will have a quadrant cut out of them, which form a semi-circular gap in the middle when the panels are sewn together. At the base of this gap is the closure (usually a fabric strap or a plastic snap mechanism), which the wearer uses to adjust the size of the cap. The front panels usually have a Buckram behind them to provide structure to the cap, maintaining their round shape. This leaves the two side panels as the simplest (from a technical perspective), as they are just pieces of fabric which have been cut into triangles. Here, we are providing information about the panels for the most common cap shape. To see the different types of cap shape we can create for you, click the link to see: Cap Shapes.
Visor is the technical term, but this part is also known as the “peak”, “brim”, and “bill”. This protects the wearer’s face from sunlight, and minimises glare to improve visibility. It can be flat or curved, round or square. It is normally created by wrapping a piece of plastic with the desired fabric(s), however even the visor style can be tweaked. One example is a sandwich-style visor in which, like the name suggests, an extra layer is added between the top and bottom layers of fabric. This allows the new middle layer (let’s call it the “filling”), to be customised to either be a different colour to the surrounding layers, and/or to be customised with printed text along the visible part of the “filling”. Another popular customisation is to have the underside of the visor coloured differently to the top layer, creating a contrast. There is usually a 4-8 row stitch on the visor, and if you require, the visor can also be embroidered or printed with custom artwork. To see the different types of visor we can create for your caps, click the link to see: Visor Styles.
The closure allows the wearer to adjust the cap to the size and shape of their head, providing a perfect fit. Caps with a closure mechanism will normally have a semi-circular gap at the back of the cap, just above the closure, unless the cap has been made for a specific head circumference, in which case the cap is referred to as a Fitted Cap, which HYPERSUPPLY can also create for you. The most common closures are buckled straps and plastic snap mechanisms. From our experience, while plastic snaps are a common closure type, our clients can typically achieve higher selling prices (and sales volumes) for their caps by using a different type of closure mechanism. To see the different types of closure we can offer for your caps, click the link to see: Closure Styles.
Buckram is the stiff fabric lining the inside of the front two panels of a baseball cap, giving the cap its shape. Most baseball caps have a buckram, though not all: baseball caps with this inner lining are called “structured caps”, and caps without this lining are called “unstructured caps”. With an unstructured cap, the cap gains its shape only when worn, as the wearer’s forehead supports the “structure” of the front of the cap. Our clients see a lot of sales for unstructured caps, the most common style being the Dad Cap. Commonly, the buckram is white in colour, but this component can actually be any colour you desire. If you would rather a different colour (for example to match the rest of your cap’s design), please let us know when you Request Your Free Quote. To learn more, check our in-depth article about The Buckram.
This is the band of cloth inside the cap, which sits at the base of the cap panels and spans the circumference of the cap. This is an unseen but essential component, as it minimises the amount of sweat on the wearer’s face. Beyond just wicking away sweat, a well-made sweatband will also make the baseball cap more comfortable to wear (it is important to remember that this is the part of the cap that touches the wearer’s forehead). A high-quality sweatband will be made of “Peach Skin” polyester, and feature 4-row stitching. These sweatbands are the standard that HYPERSUPPLY provides for all customers.
This is the “button” that you see at the top of the cap, covering the interface where the six panels meet. The squatchee actually has a top and a bottom (if you look inside a baseball cap, you should see a very small, round plate of metal in the centre). Attaching the top and bottom parts protects the intersection of the panels, ensuring that the panels are held together. Not all caps will have a squatchee however, as some styles will be made to show off the panel intersection instead. Both parts of the squatchee are made from metal, with the top part covered in fabric (normally matching the fabric used for the cap’s panels – though HYPERSUPPLY can also customise this for your caps).
These are the round holes you see stitched into the top of each panel. They maintain ventilation by allowing air to diffuse in and out of the cap, helping to keep the wearer’s head cool. Even these can be customised: Instead of just being sewn into the cap, the eyelets can also be punched with metal rivets, giving the panels a unique look and feel. The panels in a baseball cap won’t always have eyelets however: Generally, when a cap has mesh panels both at the sides and at the back (such as with a Trucker Cap), the front panels won’t have eyelets, because enough ventilation is already being provided by the mesh panels. To see the different types of eyelets HYPERSUPPLY can offer for your custom caps, click the link to see: Eyelets.
When the panels of the cap are stitched together, the seams where the panels are joined look rather unsightly, and are also left exposed. The natural solution is to cover these seams with seam tape. As well as protecting these seams, seam tape also gives the inside of your caps a professional-looking finish when it is custom-branded. If your caps will have a buckram, then the seam tape going down the buckram will actually be just for cosmetic purposes (remember that the buckram is already covering the seam between the front two panels – to understand more, check our in-depth article on The Buckram). Just like the other parts of a cap, HYPERSUPPLY can customise your cap’s seam tape. Make sure you include your design requirements for seam tape in the files you upload when you Request Your Free Quote.