CUTTING ROOM

Step 1: Fabric Is cut.

BUNDLING

Step 2: Pieces are bundled together to create cap.

SEW FRONT BACK

Step 3: Front and back panels are sewn together.

TAPE FRONT BACK

Step 4: Fabric is applied to the front and back seams to cover exposed edges.

HAIRCLOTH COVERS

Step 5: Two panels of haircloth fabric are sewn together.

HAIRCLOTH TAPE

Step 6: As in Step 4, Fabric is applied

PEAK MADE

Step 7: The visor fabric is sewn together with a visor board inserted in between.

PEAK STITCH

Step 8: Approximately eight rows of stitching are applied to the visor.

EMBROIDERY

Step 9: Logos are added.

FUSING

Step 10: TOP SECRET!

EYELETS

Step 11: The stitching is sewn around the pre-punched eyelet hole.

COVERS

Step 12: The crown is created with a middle panel sewn to the front and back panels.

COMPLETE TAPE

Step 13: As in Steps 4 and 6, fabric is then applied to the seams.

SIZING

Step 14: A premeasured strip is applied to the base of the crown to make it a specific size.

ATTACH PEAK

Step 15: The crown and visor are attached.

ATTACH SWEAT BAND

Step 16: Sweatband is added to the base of the crown.

BARTACKS LABEL

Step 17: Labels are sewn evenly together.

TOP STITCH

Step 18: Decorative top stitch is applied to the base of the cap.

BUTTONS

Step 19: A button is applied to the top of the cap.

BLOCKING

Step 20: The cap is placed on a blocking machine to ensure size, steamed and placed on a cooling rack.

PACKING

Step 21: The cap is packed with a visor sticker after final inspection.

THE PERFECT CAP