Snapback
Fabric
Organic Cotton, Recycled Polyester, Hemp Fabrics
Embroidery
High Density Embroidery Machine
Printing
Screen Printing, Thermal Transfer, Digital Direct Printing, Etc.
ECO
Organic Cotton, Recycled Polyester, Etc
- 1. Design & Material Selection
- Components:
- Crown: 5–6 fabric panels (polyester, cotton, wool, or blends).
- Brim: Hard plastic or cardboard core wrapped in fabric.
- Sweatband: Moisture-wicking fabric (terry cloth, faux leather).
- Closure: Adjustable plastic snapback strap with 4–6 snaps.
- Eyelets: Metal or plastic grommets for ventilation.
- Sustainability: Organic cotton, recycled polyester, or hemp fabrics.
2. Pattern Making & Cutting- Panel Templates: Create digital patterns for crown panels, brim, and sweatband.
- Fabric Cutting:
- Laser or die-cutting machines ensure precision.
- Panels are cut with seam allowances (3–5 mm).
3. Crown Assembly- Panel Stitching: Sew panels together using lockstitch machines, forming the crown.
- Brim Attachment:
- Stitch the brim core (plastic or stiffener) to the front panels.
- Wrap with fabric and topstitch for a clean finish.
- Sweatband Installation: Sew the sweatband to the crown’s inner edge for comfort.
4. Snapback Closure & Adjuster- Strap Construction:
- Cut a fabric strip (polyester or nylon) and attach plastic snaps.
- Sew the strap to the hat’s rear panels.
- Adjuster: Plastic snap buttons are secured at intervals for size customization.
5. Eyelet Installation- Punch holes in the crown panels.
- Press metal or plastic grommets into place for ventilation.
6. Embroidery & Branding- Front Logo: Digitally embroider designs using multi-head machines (e.g., 1000–3000 stitches per minute).
- Side/Back Logos: Heat transfers, screen printing, or patches for additional branding.
7. Finishing & Quality Control- Steam Pressing: Remove wrinkles and shape the hat.
- Stiffener Insertion (for structured styles): Add foam or buckram to maintain crown shape.
- Fit Testing: Check snap closure adjustability and crown dimensions.
- Durability Checks: Inspect seams, snaps, and fabric for defects.
8. Packaging- Retail-Ready: Fold and stack hats in branded boxes or hang tags.
- Customization: Add branded tissue paper, stickers, or care instructions.
- Components:
