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How to Sew a Baseball Cap

By Alex Berryman

When it comes to caps, quality construction is paramount. The sewing quality and resulting accuracy of the fit will ultimately be what makes your customer come back to re-order.

We are peeking behind the curtain, going through the construction of Purnaa's 200 Lo-Pro Trucker Cap step by step so that you can see how we ensure quality in every aspect of the cap. For the sake of clarity, we will refer to each of the 6 panels using the photo below :

Step 1 - Sublimation

In the case of the Lo-Pro Trucker, only the front panels (1 and 2), visor panels, and button cover are sublimated. The print file is first printed on a large piece of paper, then set on top of the poleyster fabric, and run through the heat press. The ink will transfer from the paper onto the cap, ensuring a vibrant, colorfast print.

Step 2 - Add Buckram to Front Panels

The printed fabric is then cut into segments - segment one is the two front panels (1 and 2), segment two is the visor panels and button. Segment one is placed facedown with sheets of buckram placed on the unprinted side. The panels and buckram are pressed in a heat press for 1 minute - this ensures the buckram adheres to the fabric, without folding or bubbling.

Step 3 - Cutting

Each segment is then cut using a dye press and stacked for sewing. Since Purnaa processes multiple different prints and orders per day, it is important to keep the cut pieces together as a set.

Step 4- Sewing Front and Back Panels

While printed pieces are being cut, the sewing teams sew pieces 4 and 5 to create the back panels of the cap.

Once cut pieces arrive from the dye press, panels 1 and 2 are joined and sewn together - ensuring the print is aligned correctly on the outward-facing side.

Step 5 - Taping

Taping is then applied between panels 1 and 2, and panels 3 and 4 (if not already done so in sewing preparation). This ensures the rough edges of the fabric lay flat, making it more comfortable for the wearer and giving it a finished look.

Step 6 - Construct the Crown

Side panels ( 3 and 6) are then sewn to the front and back pieces (respectively) creating two halves of the crown.

The two halves are then joined to create the crown. The cap is constructed in this way to ensure a consistent fit and size across a production run, as well as reduce waste of material.

Step 7 - Final taping

Taping is added to this final seam, smoothing the apex point on the top of the crown, giving it a more finished look. It is also done at this point to maintain the defining profile of the cap and to provide overall structure.

Step 8 - Add Size Strip

A size strip is sewn around the base of the crown, providing stability for the mesh. Without the size strip, the mesh could stretch diagonally, changing the shape and fit of the cap.

Step 9 -Sew Visor and Add Visor Stitches

First, the visor covers are sewn together and turned "right side out". The pre-curved visor is inserted, then sealed tightly in place with a topstitch.

Visor stitches are then added on top of the visor, using a special attachment to create consistent spacing and placement. These stitches ensure the fabric does not stretch away from the visor, maintaining that classic baseball cap look.

Step 10 - Attach the Visor to the Cap

First, the visor must be centered and tacked down using a simple topstitch.

Once placed correctly, the visor is then joined to the cap using a post machine. It is essential that the visor lines up perfectly and the seam allowance is consistent across the visor, or it will not sit on the cap correctly.

Step 11 - Add the Sweatband

The sweatband is sewn to the raw edge of the panels. The sewing technician pays careful attention to stitching between panels 1 and 2, and the visor - if not done just right, stitches could be seen on the outside of the cap.

Step 12- Run a Top Stitch on the Crown

The sewer runs a stitch across panels 1 and 2, tacking down the sweatband. This ensures the sweatband doesn't turn out when worn and stabilizes raw edges, making it more comfortable wearer.

Step 13 - Attach the Snaps

The final raw edges of the sweatband are turned in, creating a hem that lines up with the back opening. The snaps are inserted into the hem and sewn.

As you can see, the cap is a high labor product which makes it reliant on the skills and the systems of the manufacturer. Purnaa has worked tirelessly to create systems that deliver on this quality quickly. With our sublimation system, you can easily source ethically made, sublimated baseball caps with an MOQ of 12 and shipped within 2 weeks. If you would like to know more about the styles we offer or would like to start an inquiry, check out our webpage.


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