Cap block
Six-panel caps: structured and unstructured
The six-panel cap is the shape most buyers picture when they say "baseball cap" — two front panels with a centre seam. The decisions that actually change the product are the crown structure, the fabric weight and the closure, and this block covers all three with numbers.
Specification
| Panels | 6 panels, mid-profile crown 11–12 cm |
|---|---|
| Crown types | Structured (front two panels interlined) or unstructured (soft, packable) |
| Fabric weight | 180–320 gsm cotton twill; 200–260 gsm performance nylon; 280–350 gsm corduroy |
| Brim | Curved, 6.5–7.5 cm; pre-curved or flat |
| Closure | Metal slide, plastic snapback, Velcro, elastic band, or fitted (no closure) |
| Sizes | One size 56–60 cm adjustable; or fitted 54/56/58/60 cm |
| Decoration | Flat embroidery, 3D puff, applique, woven patch, leather patch, PVC patch, screen print, heat transfer, sublimation |
| Eyelets | 6 sewn eyelets standard; embroidered eyelets on request |
Crown type by use — what to specify
| Crown | Shape | Packs flat | Best for |
|---|---|---|---|
| Structured, mid-profile | Holds shape | No | Retail, team, corporate |
| Unstructured, low-profile | Soft | Yes | Dad caps, promotional |
| Structured, high-profile | Tall front | No | Streetwear, snapback |
| Unstructured, washed | Soft, faded | Yes | Casual, event |
Fabrication, fabric and decoration
Fabrication
- Cutting
- Panel sewing
- Crown joining
- Eyelet setting
- Brim layup and pressing
- Sweatband sewing
- Closure fitting
- Final press
Fabrics
- Cotton twill 180–320 gsm
- Brushed cotton
- Performance nylon
- Polyester mesh
- Corduroy 8–14 wale
- Canvas
- Linen blend
Decoration
- Flat embroidery
- 3D puff embroidery
- Applique
- Woven patch
- Leather patch
- PVC patch
- Screen print
- Heat transfer
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 6-panel caps
- Custom baseball hats
- Custom dad hats
- Custom snapbacks
- Custom trucker hats
- Custom fitted hats
- Custom corduroy hats
- Custom performance caps
Reading for this block
- Cap panel guide
- Crown height guide
- Cap fabric weight guide
- Cap closure guide
- 5-panel vs 6-panel
- Cap specifications
Questions
Structured or unstructured — which should I choose?
Structured if the cap has to hold a shape on a shelf or in a team photo; unstructured if it has to pack flat, ship cheaply, or sit softly on the head. Structured adds an interlining to the front two panels, which is a small cost per piece and a large difference in how the cap reads.
What fabric weight is right for a retail cap?
260–320 gsm cotton twill for a cap that must feel substantial; 180–220 gsm for a summer or promotional cap. Below 180 gsm the crown collapses and the embroidery pulls the panel.
What is the minimum order for a custom six-panel cap?
100 pieces per style and colour, because the cutting and embroidery setup is amortised across the run. Below that the setup dominates the price.
Can the cap be made in several sizes rather than one-size-fits-all?
Yes, in 54 / 56 / 58 / 60 cm with no closure. A size run fits better and removes the strap, but it multiplies the SKU count by four — worth it above about 3,000 pieces per colour.
Start a six-panel caps programme
100 pieces per style and colour · sampling in 7–10 days · production in 25–35 days · quote within one business day.