Cap block
Custom bucket hats and sun hats
A bucket hat is a brim problem: the down-turned brim has to keep its shape in a bag and still shade the face, and the crown has to stay cool without a structured front. This block is the construction and the numbers.
Specification
| Construction | 4-panel or 6-panel crown; down-turned brim |
|---|---|
| Brim width | 5–8 cm; wider brims need a stiffer interlining |
| Fabric weight | 200–320 gsm cotton twill or canvas; 180–220 gsm nylon |
| Lining | Unlined, mesh-lined or full cotton lining |
| Extras | Chin cord, toggle, eyelets, internal sweatband, packable fold line |
| Sizes | One size 56–58 cm; or S/M (56–57) and L/XL (58–60) |
| Decoration | Front embroidery, brim-edge embroidery, woven label, screen print, all-over print on nylon |
Brim and lining by use
| Use | Brim | Lining | Note |
|---|---|---|---|
| Retail summer | 6 cm | Cotton | Holds shape on shelf |
| Resort / promotional | 6–7 cm | Unlined | Lowest cost |
| Fishing / outdoor | 7–8 cm | Mesh | Wider brim, cooler crown |
| Packable travel | 6 cm | Unlined | Soft interlining, folds flat |
Fabrication, fabric and decoration
Fabrication
- Cutting
- Crown sewing
- Brim layup
- Brim joining
- Eyelet setting
- Sweatband sewing
- Final press
Fabrics
- Cotton twill
- Canvas
- Nylon
- Ripstop
- Terry cloth (brim lining)
- Corduroy
Decoration
- Flat embroidery
- Woven label
- Screen print
- All-over print
- Applique
How it is quoted
| Minimum order | 100 pieces per style and colour |
|---|---|
| Sampling | 7–10 days after artwork approval, sample cost refundable on the bulk order |
| Production | 25–35 days after sample approval |
| Quote turnaround | Within one business day, with a spec sheet |
Styles in this block
Reading for this block
- Cap brim shapes guide
- Cap fabric guide
- Cap storage and care guide
- How to clean a custom cap
- Wide brim sun visors
Questions
How do I make a bucket hat packable?
Use a soft brim interlining instead of a stiff board, and specify that the brim is not pressed flat. The trade-off is that a packable brim shades less crisply — the same trade a firm cap brim makes in reverse.
What brim width should I specify?
6 cm for retail and 7–8 cm for outdoor use. Wider than 8 cm needs a stiffer interlining, which makes the hat harder to fold and more expensive to ship.
Can the bucket hat be lined?
Yes — unlined, mesh-lined for hot climates, or full cotton lining for a premium feel. Lining changes the weight and the cost per piece, and it changes the fit slightly because it takes up space in the crown.
Start a bucket hats programme
100 pieces per style and colour · sampling in 7–10 days · production in 25–35 days · quote within one business day.