How Are Baseball Caps Made?

This may seem like a silly question but we’re going to pose it anyhow… What is a baseball cap?

Well, it protects your eyes from the sun with a visor. Several sections of fabric are sewn together to make up the semi-flexible fabric crown. It is considered a “soft hat”. In specific sizes, to fit a particular wearer, some caps are specially made. Overall, however, according to the wearer's needs, to make the hat smaller or bigger, at the center-back you will find a plastic or cloth extender. On the top of the crown sits a fabric covered button. This is the convergence point for all the sewn together fabric sections. Embroidered on the crown’s face (front), you may find team logos, letters, cartoon characters, and more.

The Process of Manufacturing

Without further delay, here are the manufacturing steps used to put together baseball caps:

1. Fabric layers which – depending on the style and company – can be a cotton synthetic mix, cotton, or wool, are cut.
2. In some cases, behind the two front panels, a mesh interlayer is added. Before the panels are sewn together, the mesh is put against the back of the panels.
3. Crown sections (usually long, triangular shaped fabric sections) are sent to have small holes pierced into each of them (and the edges bound) by the eyelet department. Anywhere from one to 50 holes may be punched in each section. These are vents that allow your head to cool when you perspire.
4. The embroidery department next receives the two front panels. Onto them, a word, a logo, a picture, etc., are machine embroidered using computer works. In some of the more complicated embroidery projects, as much as 31,000 stitches might be used!
5. Either eight or six panels, ordinarily, belonging to the crown are stitched together by the sewing department. Though the hat is not complete, the soft crown is. It still needs a visor.
6. With binding tape, raw seams are hidden/covered. As well as security against washing, perspiration, hardware, etc., it gives the hat a finished look.
7. A fabric-covered galvanized steel button is then added to the top of the hat, at dead center.
8. According to their desired size, visors are die-cut then sewn to the cap. Visor stiffness can vary from company to company.
9. In the back of the cap, an adjustable plastic (or cloth) band is sewn into "one-size-fits-all" hats.

In various sizes, at the back of the caps, the front sections are sewn together to create specific sizes. These are referred to as fitted caps.

10. Finally, inside the cap, a sweatband is sewn. If required, at this time, a label may be added.
11. To ensure superior products, different variations are included or added to this process by some companies.

Baseball Caps Made With Quality in Mind

Now that you know how baseball caps are made, here's where to shop for the best made baseball caps.

At Hat Heaven, we carry some of the most well-known brands in headwear. From cotton to wool caps, our headwear comes in various color choices, is top-of-the-line, and represents numerous professional and college sports. Feel free to peruse our vast selection today.