Cap Shapes & Styles
Bill Shapes
Curved Bill
Classic curved brim offering sun protection and traditional baseball cap aesthetic.
Characteristics:
- Pre-curved brim
- Versatile style
- Most popular option
Best for: Casual wear, sports teams, promotional items
Flat Bill
Modern flat brim style popular in street fashion and hip-hop culture.
Characteristics:
- Completely flat brim
- Contemporary look
- Often worn with stickers intact
Best for: Urban fashion brands, youth market, trendy promotions
Slight Curved
Subtle curve that balances classic and modern aesthetics.
Characteristics:
- Gentle curve
- Professional appearance
- Minimal break-in needed
Best for: Corporate branding, golf, upscale casual
Profile Heights
High Profile
Traditional tall crown providing maximum embroidery space.
Measurements:
- Crown height: 3.5" - 4"
- Extra room for logos
- Classic silhouette
Best for: Large logo embroidery, traditional sports teams
Mid Profile
Balanced height suitable for most applications.
Measurements:
- Crown height: 3" - 3.5"
- Versatile fit
- Modern proportions
Best for: Most applications, retail products, standard branding
Low Profile
Sleek, contemporary profile sitting closer to head.
Measurements:
- Crown height: 2.5" - 3"
- Streamlined look
- Tight fit
Best for: Fashion brands, fitted styles, minimalist designs
Panel Configurations
5-Panel
Modern construction with front panel extending over sides.
Features:
- Single front panel
- Minimal seams
- Contemporary design
- Popular in fashion/streetwear
6-Panel
Classic construction most common in baseball caps.
Features:
- Traditional look
- Balanced panel distribution
- Industry standard
- Maximum versatility
7-Panel
Unique construction with center front panel.
Features:
- Distinctive appearance
- Center branding opportunity
- Specialty option
- Premium positioning
Structure Types
Structured
Stiff front panel maintains shape.
Characteristics:
- Built-in stiffener
- Holds form when off head
- Professional appearance
- Premium feel
Applications: Corporate branding, retail, premium products
Unstructured
Soft construction that conforms to head.
Characteristics:
- No stiffener
- Relaxed fit
- Casual appearance
- Packable
Applications: Casual brands, dad hats, vintage style
Foam Front
Front panel backed with foam for support.
Characteristics:
- Lightweight support
- Trucker cap style
- Breathable
- Sporty look
Applications: Outdoor brands, trucker caps, athletic wear
Closure Types
Snapback
Adjustable plastic snap closure.
Features:
- One-size-fits-most
- Easy adjustment
- Durable
- Classic style
Sizes: Typically adjusts 6 3/4" - 8"
Velcro (Hook & Loop)
Fabric strap with velcro closure.
Features:
- Infinite adjustment within range
- Soft closure
- Comfortable
- Modern option
Best for: Sports, active wear, comfort-focused designs
Fitted
No adjustment - sized to specific measurements.
Features:
- Clean appearance
- Premium feel
- Perfect fit when sized correctly
- No back closure
Available Sizes: 6 3/4" - 8" (1/8" increments)
Stretch Fit
Elastic band for flexible sizing.
Features:
- Flexible sizing (S/M/L/XL)
- Comfortable fit
- No adjustment needed
- Active wear friendly
Fabric Options
Cotton Twill
Classic fabric, durable and soft.
- Weight: Medium
- Feel: Soft, structured
- Durability: Excellent
- Applications: All-purpose
Polyester
Performance fabric with moisture-wicking.
- Weight: Light to medium
- Feel: Smooth, technical
- Durability: Excellent
- Applications: Sports, outdoor
Mesh
Breathable trucker-style backing.
- Weight: Very light
- Feel: Airy, cool
- Durability: Good
- Applications: Summer wear, trucker caps
Wool Blend
Premium fabric for upscale products.
- Weight: Medium to heavy
- Feel: Soft, luxurious
- Durability: Excellent
- Applications: Fashion, premium brands
Special Constructions
Trucker Cap
- 5 or 6 panel front
- Mesh back panels
- Foam front support
- Snapback closure
Dad Hat
- Unstructured 6-panel
- Curved bill
- Adjustable strap
- Relaxed fit
5-Panel Camp Cap
- Flat front panel
- Flat or slight curved bill
- Fashion-forward
- Often unstructured
Rope Cap
- Decorative rope on bill
- Nautical/outdoor theme
- Typically cotton twill
- Classic snapback
Choosing the Right Style
By Use Case
Sports Teams:
- 6-panel, mid or high profile
- Structured or foam front
- Curved bill
- Snapback or fitted
Corporate Branding:
- 6-panel, mid profile
- Structured
- Slight curved or curved bill
- Velcro or snapback
Fashion/Retail:
- 5-panel or 6-panel
- Unstructured (dad hat style)
- Flat or curved bill
- Varied closures
Outdoor/Performance:
- 6-panel, trucker style
- Foam front with mesh
- Curved bill
- Snapback
Need Help Choosing? Contact our product specialists at products@customcapbd.com View Samples: Visit our Product Catalog