Cap block
Five-panel caps and camp caps
The five-panel cap has a single flat front panel, which makes it the best canvas for a wide logo, a full-width print or a woven patch. It is also the shape that reads most like a piece of apparel rather than a sports cap.
Specification
| Panels | 5 panels, flat front panel |
|---|---|
| Crown | Unstructured, low to mid profile; 9–11 cm |
| Fabric weight | 200–320 gsm cotton, canvas, nylon or ripstop |
| Brim | Curved or flat, 6–7 cm |
| Closure | Strap with metal slide or plastic clip; elastic back on camp caps |
| Decoration area | Front panel up to 90 × 60 mm for embroidery; edge-to-edge for print or patch |
| Typical use | Brand merch, camp and outdoor, café and brewery, retail apparel lines |
Five-panel versus six-panel — when the flat front matters
| Feature | Five-panel | Six-panel |
|---|---|---|
| Front panel | One flat panel | Two panels + centre seam |
| Wide logo | Best — no seam | Seam splits wide logos |
| Shape | Soft, unstructured | Can be structured |
| Packs flat | Yes | Only if unstructured |
| Reads as | Apparel / streetwear | Sports / classic |
Fabrication, fabric and decoration
Fabrication
- Cutting
- Front panel preparation
- Crown joining
- Brim layup
- Sweatband sewing
- Closure fitting
- Final press
Fabrics
- Cotton twill
- Canvas 10–16 oz
- Nylon
- Ripstop
- Corduroy
- Linen blend
Decoration
- Flat embroidery
- Woven patch
- Leather patch
- Screen print
- Heat transfer
- 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
- Custom 5-panel caps
- Custom camo hats
- Brewery hats
- Custom low-profile caps
- Custom rope hats
- Custom applique caps
- Woven patch hats
- Leather patch hats
Reading for this block
- Cap panel guide
- Cap style comparison chart
- Cap decoration guide
- Embroidery vs patch vs printing
- Cap brim shapes guide
Questions
Why choose five-panel over six-panel?
The flat front panel. A wide logo or a full-width print crosses the centre seam on a six-panel cap and has to be split or shrunk; on a five-panel it sits on one uninterrupted surface.
Can a five-panel cap be structured?
It can be lightly interlined, but the point of the shape is the soft crown. If you need a cap that holds a tall rigid front, a structured six-panel or a snapback is the right product.
What decoration suits a flat front panel best?
Woven or leather patches for a premium look, screen print for large flat graphics, and flat embroidery for a logo up to about 90 × 60 mm. 3D puff works but competes with the flat panel design.
Start a five-panel and camp caps programme
100 pieces per style and colour · sampling in 7–10 days · production in 25–35 days · quote within one business day.