Methods and apparatus for preparing a host article and a decorative patch for removable attachment to one another using snap fasteners. In one example, a method includes simultaneously punching a first plurality of holes arranged in a first pattern into a front surface of the host article, positioning a plurality of host snap fasteners in the first plurality of holes, and simultaneously setting the plurality of host snap fasteners to secure the plurality of host snap fasteners to the host article. The method further includes simultaneously punching a second plurality of holes in a corresponding second pattern into a decorative patch and setting a plurality of patch snap fasteners in the second plurality of holes to secure the plurality of patch snap fasteners to the decorative patch, the plurality of patch snap fasteners being configured to mate with the plurality of host snap fasteners to removably attach the decorative patch to the host article.

A headwear insert, system, and methods to define and control the shape of an article of headwear are provided which may be used to change the shape of an already manufactured cap to the shape of the insert, completely changing the shape and style, and the headwear insert may include an elongated body having a first end, a second end, an elongated upper surface, an elongated lower surface, an elongated first side surface, an elongated second side surface, and a curved body section. The elongated upper surface, the elongated lower surface, the elongated first side surface, and the elongated second side surface may each extend between the first end and the second end, and the curved body section may be formed by a first portion of the elongated upper surface having a convex curve shape and by a first portion of the elongated lower surface having a concave curve shape.

A headwear insert, system, and methods to define and control the shape of an article of headwear are provided which may be used to change the shape of an already manufactured cap to the shape of the insert, completely changing the shape and style, and the headwear insert may include an elongated body having a first end, a second end, an elongated upper surface, an elongated lower surface, an elongated first side surface, an elongated second side surface, and a curved body section. The elongated upper surface, the elongated lower surface, the elongated first side surface, and the elongated second side surface may each extend between the first end and the second end, and the curved body section may be formed by a first portion of the elongated upper surface having a convex curve shape and by a first portion of the elongated lower surface having a concave curve shape.

Disclosed are a hat and a manufacturing method therefor and a hat top shaping device, the hat comprising: a seamless hat top without seams, wherein same is integrally formed by hot stretching a piece of a flat knitted fabric blank containing a vitrifiable petroleum chemical fibre material; and a bongrace jointed to the seamless hat top. The hat top of the hat can save on the production time and cost. The hat top of the hat can be made into various hat types and a variety of raw materials can be selected for same. The hat top of the hat is a hat top without seams, completely fitting the user's headform, and can be made by selecting a breathable material, thereby improving the aesthetics and comfort when wearing same.

Disclosed are a hat and a manufacturing method therefor and a hat top shaping device, the hat comprising: a seamless hat top without seams, wherein same is integrally formed by hot stretching a piece of a flat knitted fabric blank containing a vitrifiable petroleum chemical fibre material; and a bongrace jointed to the seamless hat top. The hat top of the hat can save on the production time and cost. The hat top of the hat can be made into various hat types and a variety of raw materials can be selected for same. The hat top of the hat is a hat top without seams, completely fitting the user's headform, and can be made by selecting a breathable material, thereby improving the aesthetics and comfort when wearing same.

A ball cap with a concealed opening that allows for a greater variety of hairstyles to be worn while simultaneously retaining the general shape, appearance, and functionality of a typical ball cap. The concealed opening is hidden in a default configuration of the hat, but it can be selectively opened to allow for hair such as a ponytail to pass through. The ball cap can include a protective coating on the sweatband to prevent makeup, sweat, and dirt from soiling the sweatband.

A ball cap with a concealed opening that allows for a greater variety of hairstyles to be worn while simultaneously retaining the general shape, appearance, and functionality of a typical ball cap. The concealed opening is hidden in a default configuration of the hat, but it can be selectively opened to allow for hair such as a ponytail to pass through. The ball cap can include a protective coating on the sweatband to prevent makeup, sweat, and dirt from soiling the sweatband.

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.

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 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.