Hat Panels
Baseball hats are constructed from panels of fabric. A typical baseball hat is made from six panels stitched together. This configuration leaves a vertical seam on the wearers forehead and any logo embroidered on the front. Some companies produce a 5 panel hats which eliminate this seam. Many embroidered golf hats use a five panel construction.
Hat Brim (or Hat Bill)
The hat bill keeps the sun out of your eyes and rain off your face. It is constructed by stitching fabric over a plastic form. There are two kinds of bills flat and curved depending the shape of the plastic form used.
Hat Crown
The crown is the sum of the 5 or 6 panels stitched together to make the top part of the hat. Crowns are typically structured and unstructured. A structured crown is one that has been specially reinforced with buckram fabric or plastic inside the panels to help keep the crown’s shape. An unstructured crown has no reinforcing material as a result the hat does not hold its shape. Crowns come in three different profiles or heights, short, medium, and tall. The larger the profile the easier it will be to stitch your embroidered logo. If you have a very large logo it’s best to select a tall profile hat.
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