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 hat brim includes: an upper surface; a lower surface; and a face, the face extending from an outer edge of the upper surface to an outer edge of the lower surface, a face height of the face measuring at least about . A method of manufacturing a hat includes: forming a brim, a rear edge of the brim attached to a lower edge of a crown, the brim including an upper surface; a lower surface; and a face, the face extending from an outer edge of the upper surface to an outer edge of the lower surface, a face height of the face measuring at least ; and incorporating face indicia onto the face of the brim.

A hat brim includes: an upper surface; a lower surface; and a face, the face extending from an outer edge of the upper surface to an outer edge of the lower surface, a face height of the face measuring at least about . A method of manufacturing a hat includes: forming a brim, a rear edge of the brim attached to a lower edge of a crown, the brim including an upper surface; a lower surface; and a face, the face extending from an outer edge of the upper surface to an outer edge of the lower surface, a face height of the face measuring at least ; and incorporating face indicia onto the face of the brim.

A cap logo applicator, and method of fabricating, includes a first mandrel having a front and a back, the first mandrel having a curved, non-cylindrical surface, and a relief space in the back such that when a cap is positioned on the first mandrel, a front of the cap is in contact with the non-cylindrical surface and a top of the cap extends over the relief space, and a second mandrel opposing the first mandrel and configured to apply pressure to the first mandrel. At least one of the first mandrel and the second mandrel includes a heater.

A cap logo applicator, and method of fabricating, includes a first mandrel having a front and a back, the first mandrel having a curved, non-cylindrical surface, and a relief space in the back such that when a cap is positioned on the first mandrel, a front of the cap is in contact with the non-cylindrical surface and a top of the cap extends over the relief space, and a second mandrel opposing the first mandrel and configured to apply pressure to the first mandrel. At least one of the first mandrel and the second mandrel includes a heater.

A lower mandrel for a cap logo applicator includes a structure having a curved surface and a first end and a second end, an extension extending from the first end to the second end, and a first pad positioned on an upper surface of the structure. The first pad extends radially beyond both the first end and the second end and below a lower surface of the structure.

A lower mandrel for a cap logo applicator includes a structure having a curved surface and a first end and a second end, an extension extending from the first end to the second end, and a first pad positioned on an upper surface of the structure. The first pad extends radially beyond both the first end and the second end and below a lower surface of the structure.

A headwear system for protecting a user includes a crown portion and a brim portion. The crown portion has interior and exterior surfaces bound by a perimeter and the crown portion is configured to absorb shock to a head of a wearer in the event of an impact and has a concave surface and a convex surface having an apex. The brim portion is coupled to the crown portion at the perimeter and is configured to shade portions of a user's head, neck and face from sun while shedding water in a directed and/or controlled manner. A method for producing a hat includes forming a crown portion, forming a brim portion coupled to the crown portion and applying a rubber coating to the crown portion and the brim portion.

A headwear system for protecting a user includes a crown portion and a brim portion. The crown portion has interior and exterior surfaces bound by a perimeter and the crown portion is configured to absorb shock to a head of a wearer in the event of an impact and has a concave surface and a convex surface having an apex. The brim portion is coupled to the crown portion at the perimeter and is configured to shade portions of a user's head, neck and face from sun while shedding water in a directed and/or controlled manner. A method for producing a hat includes forming a crown portion, forming a brim portion coupled to the crown portion and applying a rubber coating to the crown portion and the brim portion.