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.

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.

A collapsible hat having a brim is made by inserting a leading end portion of an elongated, three-dimensional, frame element into an opening of an annular compartment extending around an outer periphery of the brim until the leading end portion passes through another opening of the annular compartment. The leading end portion is connected to a trailing end portion to make the frame element circumferentially complete to thereby impart a three-dimensional shape to the outer periphery of the brim that corresponds to the configuration of the three-dimensional frame element.