The Manufacturing Process

  1. The fabric layers—wool, cotton, or a cotton-synthetic mix (depending on the are cut. The bundles of fabric are placed one on top of another, and then they are cut at once using a fabric-cutting saw.
  2. Some cap designs require a mesh inner layer behind the two front panels. This mesh acts as a stiffener in these front panels in order for them to stand up to the stitching requirements of the embroidered logo. The mesh is put against the back of the panels before the panels are sewn to one another.
  3. The sections of the soft crown, generally of long triangular shaped, are sent to the eyelet department where a machine pierces each panel creating a small hole and binding the hole completely with thread. These eyelets serve as breathable areas so the perspiration and heat that builds up under the cap can be released.
  4. The panels of the crown, generally six panels, are then sent to the sewing department where they are stitched together.
  5. without a visor is referred to in the industry as a “beanie.”
  6. Then, these beanies are sent to the binders or the binding department at which the raw seams of the soft crown are covered or hidden with a binding tape, generally cotton, that is applied over the raw edges of the crown. This tape gives the hat a finished look (no raw edges are seen when one examines the inside of the cap) and ensures that the seams won’t unravel due to hard wear, perspiration, or washing.
  7. A galvanized steel button is self-covered (covered over in the same color as the rest of the cap) and it is then applied at the dead center of the baseball cap on top of the beanie crown at the place in which all the sections of the cap converge.
  8. Visors are die-cut according the desired size and then sewn onto the cap next. Some companies make the visor of two pieces with a stiffener such as plastic in the center; other might put a thin stiffener inside and stitch the visor a few times for strength and to prevent the stiffener from moving around and bunching up in one spot. This is called a sandwich.
  9. Next a “one size fits all” solution is done as a closure that will be sewn as an adjustable plastic band in the back of the cap.
  10. Finally, a sweatband of some sort is sewn onto the inside of the cap. This is done on industrial grade sewing machines as well and may include placing buckram (a thick, stiff mesh fabric) behind a sweatband such as inexpensive cotton or even soft leather. A label may be added at this time as well. A label may be sewn in if needed.