Disclosed are methods for manufacturing at least portions of hats and caps, as well as at least portions of hats and caps manufactured by the disclosed methods. In examples, provided are methods for fabricating a biretta, which can include (1) forming, using a hat block, a plastic biretta hat foundation from a heat-activated low-melt polyester fiber, (2) forming, using a horn block, at least one plastic biretta horn from the same type of heat-activated low-melt polyester fiber, and (3) fastening a plastic biretta horn along an exterior ridge of the plastic biretta hat foundation. An orifice can be formed in a peak of the plastic biretta hat foundation. At least a part of the plastic biretta hat foundation can be covered with a fabric cover. A twist rope or a pom fastener can be passed through the orifice to secure the twist rope or a pom to the plastic biretta hat foundation.

Disclosed are methods for manufacturing at least portions of hats and caps, as well as at least portions of hats and caps manufactured by the disclosed methods. In examples, provided are methods for fabricating a biretta, which can include (1) forming, using a hat block, a plastic biretta hat foundation from a heat-activated low-melt polyester fiber, (2) forming, using a horn block, at least one plastic biretta horn from the same type of heat-activated low-melt polyester fiber, and (3) fastening a plastic biretta horn along an exterior ridge of the plastic biretta hat foundation. An orifice can be formed in a peak of the plastic biretta hat foundation. At least a part of the plastic biretta hat foundation can be covered with a fabric cover. A twist rope or a pom fastener can be passed through the orifice to secure the twist rope or a pom to the plastic biretta hat foundation.

A frame for a lightweight costume with air permeability, the costume, and a method for manufacturing them. The frame body for the costume includes a main body made of synthetic resin and a plurality of through holes penetrating the main body. The method includes a mold installation step of installing a mold in a predetermined three-dimensional shape on an elevating table, a resin member mounting step of mounting a resin member on a pedestal, a cover mounting step of mounting a cover covering the surface of the resin member on the pedestal, a heating step of heating the resin member and the cover, a vacuum molding step of bringing the mold into contact with the back surface of the resin member and then depressurizing the inside of the chamber, and a mold release step of releasing the frame body and the cover from the mold.

A manufacturing method including providing a mould including at least two mould parts having first and second moulding surfaces which are complementarily profiled to give shape to headwear; shaping a first substrate in the mould resulting in the first substrate having a non-planar profile which matches at least a portion of the profile of the moulding surfaces;shaping a second substrate in the mould resulting in the second substrate having a non-planar profile which matches the profile of the moulding surfaces; overlaying the first substrate on the second substrate and matching their non-planar profile to form a combined substrate; placing a third substrate in the mould with the combined substrate, sandwiching the first substrate; and shaping the third substrate with the combined substrate in the mould resulting in the third substrate having a non-planar profile which matches the profile of the moulding surfaces, thereby forming a seamless structure for the headwear.

A manufacturing method including providing a mould including at least two mould parts having first and second moulding surfaces which are complementarily profiled to give shape to headwear; shaping a first substrate in the mould resulting in the first substrate having a non-planar profile which matches at least a portion of the profile of the moulding surfaces;shaping a second substrate in the mould resulting in the second substrate having a non-planar profile which matches the profile of the moulding surfaces; overlaying the first substrate on the second substrate and matching their non-planar profile to form a combined substrate; placing a third substrate in the mould with the combined substrate, sandwiching the first substrate; and shaping the third substrate with the combined substrate in the mould resulting in the third substrate having a non-planar profile which matches the profile of the moulding surfaces, thereby forming a seamless structure for the headwear.

A cap and a method for forming the same are provided. An integrally formed outer layer of fabric and an integrally formed moldable layer are adhesively bonded together to form a moldable panel. A curved edge of the moldable panel is then formed by a mold. After that, the moldable panel and at least one second panel are connected to form a crown, to which a peak is subsequently connected to form the cap. Once the curved edge of the moldable panel is formed by heating and pressure application through the mold, the integrally formed moldable layer keeps the moldable panel in shape, so there is no need to support the outer layer of fabric and curve, for example, the front panel with two pieces of buckram that are stitched together, as is conventionally required.

A cap and a method for forming the same are provided. An integrally formed outer layer of fabric and an integrally formed moldable layer are adhesively bonded together to form a moldable panel. A curved edge of the moldable panel is then formed by a mold. After that, the moldable panel and at least one second panel are connected to form a crown, to which a peak is subsequently connected to form the cap. Once the curved edge of the moldable panel is formed by heating and pressure application through the mold, the integrally formed moldable layer keeps the moldable panel in shape, so there is no need to support the outer layer of fabric and curve, for example, the front panel with two pieces of buckram that are stitched together, as is conventionally required.

A heat press includes a handle portion and a curved heat plate. That handle portion may be configured to be grasped by a user, and the curved heat (i.e., having a curved engagement surface) may be configured to engage a heat-activated design implement to transfer a design of the heat-activated design implement to a curved surface of a workpiece. Also disclosed herein, according to various embodiments, is a heat press stand having a curved floor and a hat form for supporting a workpiece (e.g., a hat) during a heat-activated design transfer using the heat press. Associated methods are also disclosed herein.

A cap and a method for forming the same are provided. An integrally formed outer layer of fabric and an integrally formed moldable layer are adhesively bonded together to form a moldable panel. A curved edge of the moldable panel is then formed by a mold. After that, the moldable panel and at least one second panel are connected to form a crown, to which a peak is subsequently connected to form the cap. Once the curved edge of the moldable panel is formed by heating and pressure application through the mold, the integrally formed moldable layer keeps the moldable panel in shape, so there is no need to support the outer layer of fabric and curve, for example, the front panel with two pieces of buckram that are stitched together, as is conventionally required.

A cap and a method for forming the same are provided. An integrally formed outer layer of fabric and an integrally formed moldable layer are adhesively bonded together to form a moldable panel. A curved edge of the moldable panel is then formed by a mold. After that, the moldable panel and at least one second panel are connected to form a crown, to which a peak is subsequently connected to form the cap. Once the curved edge of the moldable panel is formed by heating and pressure application through the mold, the integrally formed moldable layer keeps the moldable panel in shape, so there is no need to support the outer layer of fabric and curve, for example, the front panel with two pieces of buckram that are stitched together, as is conventionally required.