Every Part of a Baseball Cap Explained (So You Can Build a Better One)

If you’re running a premium hat brand—like Melin, New Era, ’47 Brand, or Sunday Swagger—you already know: details matter. Your customers aren’t just buying a cap. They’re buying feel, fit, and finish.

So what actually makes a well-built cap? And what should you pay attention to if you’re building your own line?

Whether you’re just starting your private label brand or want to upgrade what you’ve already got, here’s a breakdown of every part of a baseball cap—what it does, how it works, and why it matters.

A solid baseball cap is made of several key parts: the crown (usually 5 or 6 panels), the visor or brim, a top button, ventilation eyelets, a sweatband inside, and an adjustable or fitted closure at the back. Premium caps might also have extra touches like sandwich visors, custom seam tape, and either structured or unstructured construction depending on the style.

Structured vs. Unstructured Caps — What’s the Real Difference?

Let’s start with a question we hear a lot—what’s the deal with structured vs. unstructured?

• Structured caps have a reinforced front panel (usually with buckram) that holds the shape. Think athletic, bold, street-ready.
• Unstructured caps don’t have that stiff front, so they fit closer to the head and give off a more relaxed, lived-in vibe.

En ÚneteTop, we make both. Whether you’re going for laid-back or buttoned-up, we’ll help you match the build to your brand style.

Designing a Cap That Feels Like Your Brand

Designing a cap isn’t just about how it looks. It’s about how it feels—in your hand, on your head, and in your lineup.

Here are a few tips if you’re working with a custom cap manufacturer:

• Choose a profile (low, mid, or high) that matches your customer base
• Go structured if you want it crisp, or unstructured if you’re going casual
• Use things like underbrim prints or sandwich visors to sneak in extra branding
• Don’t forget the inside—custom sweatbands, seam tape, even inside labels can make your hat feel premium without shouting about it

Want more tips like this? Check out our cap manufacturing blog for behind-the-scenes insights.

Let’s Break Down the Cap—Part by Part

Crown

This is the body of the cap. Most are made of 5 or 6 sewn panels that come together at the top. The shape of the crown defines how your cap fits and looks—from low-profile to deep-fit.

Here’s a deeper dive on crown types.

Visor / Brim / Bill

It blocks the sun and adds style. Flat? Curved? Pre-bent? Up to you.

We’ve seen brands go bold with contrast stitching, printed underbrims, and eco-friendly inserts. Want something clean or performance-driven? We’ve got options.

Button (Squatchee)

That little button at the top? It keeps the panels together and completes the look. You can color-match it, contrast it, or even embroider it. Small detail—big finish.

Ojales

Eyelets = ventilation. They help your cap breathe. You can go classic with stitched holes or modern with metal grommets. Want mesh back panels instead? That works too.

Sweatband

This is where comfort lives. It absorbs sweat and gives structure. Options? Tons. From brushed cotton to performance mesh to bamboo blends if you’re aiming for a sustainable angle.

Also, don’t sleep on the interior branding. Seam tape, printed logos, hidden labels—it’s all real estate.

Need help choosing? Here’s a good guide to sizing and fit.

Cierre

Snapback, strapback, or fitted?

• Snapbacks are adjustable and classic
• Strapbacks (leather or fabric) lean vintage
• Fitted caps have that clean, pro feel—no adjustments needed

We can do custom hardware, laser-engraved buckles, hidden Velcro—you name it.

For streetwear-focused collections, check out our custom streetwear caps.

Extra Features That Give You an Edge

Want to stand out? These are the upgrades that turn heads:

• 3D puff or flat embroidery
• Rubber or woven patches
• Reflective details
• Custom printed seam tape
• Fully branded hang tags and packaging

At JoinTop, we’ve helped brands launch with just a few hundred units and scale to tens of thousands. We’ll guide you through what makes sense based on your audience and price point.

Global Production, Local Feel

We get it—production overseas sounds complicated. That’s where we come in.

JoinTop has factories in China, Vietnam, and Bangladesh, which gives us flexibility on lead times, materials, and pricing. But our communication? Always clear and local. We’ve worked with brands across the U.S. and know how to bridge the gap.

Whether you’re doing a small DTC drop or need 20,000 units for retail, we’ve got your back.

Learn more about working with a custom cap manufacturer that actually gets your business.

PREGUNTAS FRECUENTES

What are the parts of a baseball cap?

Crown, visor (or brim), top button, eyelets, sweatband, and closure. Some premium caps also have custom seam tape or sandwich visors. Here’s a breakdown from Flexfit.

What’s the difference between structured and unstructured?

Structured = holds shape. Unstructured = soft and casual. It mostly comes down to the feel and audience you’re targeting.

Can I make private label hats with my own design?

Absolutely. We’ve helped dozens of brands do it. From fabric selection to packaging—we guide you through every step.

How do I choose the right cap for my brand?

Think about your customer. Sporty? Go structured. Chill? Go soft. Want eco points? Try sustainable materials. We’ll help you dial it in.

There are a lot of ways to build a cap. But only one way to do it right: understand the pieces, make the right calls, and work with a factory that actually listens.

JoinTop has been helping brands—big and small—design, produce, and deliver custom caps that fit both heads and business goals.

Have a concept you want to bring to life? Get in touch and let’s make it happen.