A system for creating a covered hat using an upper form having a top surface, a bottom edge, and side walls having an elongated cylindrical shape between the top surface and bottom edge. A stand having an upper block is inserted into the upper form against the top surface. A rigid ring insert is placed within the form and aligned with the bottom edge. A covering sheet made of a textile material having outer edges is centered over the top surface of the upper form. A rope band secures the covering sheet tightly against the upper form and is aligned with the ring insert. The outer edges are pulled downwardly to remove wrinkles, the covering sheet is stitched in place to the upper form, and the upper form is severed just above the ring for subsequent attachment to a hat lower part.

A method is providing for manufacturing an integrally formed cap, the method comprising: in step 1, providing a shell fabric B and a thermoplastic lining fabric C, superposing the shell fabric on a surface of the lining fabric and tightly attaching the shell fabric to the lining fabric, to obtain the fabric A needed, and providing the shaping mold matched with the shape of a cap; in step 2, cutting the fabric A obtained in Step 1 into set dimensions; and in step 3, tightly attaching the fabric A cut in Step 2 onto the shaping mold obtained in Step 1, thermally shaping the fabric A by a container, so as to integrally shape the fabric A into the cap. With the method of the invention, the production speed and quality stability can be increased, the production cost reduced, and the production process is energy-saving and environment-friendly.

A baseball cap (100) and method of assembling thereof is provided. The cap (100) includes a single-panel crown (110) that is formed from a single sheet or single piece of stretchable fabric, such as using heat pressing techniques. The single-panel crown (110) has a hemispherical shape. The cap (100) further includes a support layer (230), such as made from buckram, which is attached to an interior, front portion of the single-panel crown (110), and a visor (120) and an elastic band (260) which are attached to the single-panel crown (110).

A baseball cap (100) and method of assembling thereof is provided. The cap (100) includes a single-panel crown (110) that is formed from a single sheet or single piece of stretchable fabric, such as using heat pressing techniques. The single-panel crown (110) has a hemispherical shape. The cap (100) further includes a support layer (230), such as made from buckram, which is attached to an interior, front portion of the single-panel crown (110), and a visor (120) and an elastic band (260) which are attached to the single-panel crown (110).

A baseball cap and method of assembling thereof is provided. The cap includes a crown that is formed from a single sheet or single piece of stretchable fabric, such as using heat pressing techniques. The cap further includes a support layer, such as made from buckram, which is attached to an interior, front portion of the crown, and a visor and a band which are attached to the crown. The crown has a hemispherical shape. In one example, the crown can include a back portion thereof which has been removed to form an open area across which an adjuster is attached. In another example, a front portion of the single-panel crown can be removed and replaced with a front panel made of a different material to form a modified crown.

A baseball cap and method of assembling thereof is provided. The cap includes a crown that is formed from a single sheet or single piece of stretchable fabric, such as using heat pressing techniques. The cap further includes a support layer, such as made from buckram, which is attached to an interior, front portion of the crown, and a visor and a band which are attached to the crown. The crown has a hemispherical shape. In one example, the crown can include a back portion thereof which has been removed to form an open area across which an adjuster is attached. In another example, a front portion of the single-panel crown can be removed and replaced with a front panel made of a different material to form a modified crown.

A baseball cap and method of assembling thereof is provided. The cap includes a crown that is formed from a single sheet or single piece of stretchable fabric, such as using heat pressing techniques. The cap further includes a support layer, such as made from buckram, which is attached to an interior, front portion of the crown, and a visor and a band which are attached to the crown. The crown has a hemispherical shape. In one example, the crown can include a back portion thereof which has been removed to form an open area across which an adjuster is attached. In another example, a front portion of the single-panel crown can be removed and replaced with a front panel made of a different material to form a modified crown.

A baseball cap and method of assembling thereof is provided. The cap includes a crown that is formed from a single sheet or single piece of stretchable fabric, such as using heat pressing techniques. The cap further includes a support layer, such as made from buckram, which is attached to an interior, front portion of the crown, and a visor and a band which are attached to the crown. The crown has a hemispherical shape. In one example, the crown can include a back portion thereof which has been removed to form an open area across which an adjuster is attached. In another example, a front portion of the single-panel crown can be removed and replaced with a front panel made of a different material to form a modified crown.

A baseball cap and method of assembling thereof is provided. The cap includes a single-panel crown that is formed from a single sheet or single piece of stretchable fabric, such as using heat pressing techniques. The single-panel crown has a hemispherical shape. The cap further includes a support layer, such as made from buckram, which is attached to an interior, front portion of the single-panel crown, and a visor and an elastic band which are attached to the single-panel crown.

Disclosed is a method for manufacturing a front portion of a crown, including preparing a front left fabric section and a front right fabric section among six fabric sections of the crown, preparing a first fabric section by coupling and sewing the front left fabric section and the front right fabric section, preparing a second fabric section by combining two fabric sections taking the same shapes as the front left fabric section and the front right fabric section which constitute the third fabric section, to position the second fabric section inside the crown, to thereby maintain the shape of the crown, positioning the first fabric section outside and the second fabric section inside, and applying certain heat and pressure to a heating apparatus corresponding to a partial shape of the crown, thereby positioning the first fabric section and the second fabric section more closely to each other.