Material Library · Caps & Hats
Cap & Hat Materials
A cap or hat is made of an outer fabric, the hidden layers that give it shape, and the band that sits on the head. This page covers the fabrics, straws and components we use for custom caps and hats, from cotton twill and canvas to wool and fur felt, sherpa, linen and straw.
Updated
- 50 pcsMinimum order
- 14 daysStandard lead time
- OEKO-TEX®Fabrics from certified mills
- ISO 9001Certified (Eco Jersey Limited)
- SedexMember (Eco Jersey Limited)
Fabrics and components
Cap and hat materials we work with
Open a fabric to see what is typical for it and what we confirm for your order. Weights, colours and finishes are set for each style in the tech pack.
Cap & Hat Materials
Cotton Twill (Cap Fabric)
The standard cap fabric: a cotton woven in a diagonal twill that is firm, smooth and takes embroidery cleanly. Used for baseball, dad, six-panel, snapback and…
WovenTwillMidweight
- Warmth
- Low
- Breathability
- High
- Stretch
- Low
Cap & Hat Materials
Brushed Cotton Twill
Cotton twill with a lightly brushed surface that feels soft and slightly peach-like. It gives dad caps and relaxed six-panel caps a worn-in, comfortable feel from…
WovenTwillMidweight
- Warmth
- Moderate
- Breathability
- High
- Stretch
- Low
Cap & Hat Materials
Cotton Canvas
A heavy, tightly woven plain-weave cotton that is stiff, hard-wearing and takes on a natural texture with use. Used for bucket hats, five-panel caps, military-style caps…
WovenCanvasHeavyweight
- Warmth
- Low
- Breathability
- Moderate
- Stretch
- Low
Cap & Hat Materials
Denim (Cap Fabric)
A cotton twill dyed with indigo or other colours, in washed or raw finishes. It gives caps, bucket hats and gambler hats a casual, hard-wearing look…
WovenDenimMidweight
- Warmth
- Low
- Breathability
- Moderate
- Stretch
- Low
Cap & Hat Materials
Corduroy (Cap Fabric)
A cotton fabric with cut-pile ridges that give a soft, warm, textured surface. Popular for autumn and winter dad caps, five-panel caps, flat caps and bucket…
WovenCorduroy (cut pile)Midweight
- Warmth
- Moderate
- Breathability
- Moderate
- Stretch
- Low
Cap & Hat Materials
Nylon & Ripstop (Cap Fabric)
A light, smooth woven nylon, often with a ripstop grid, that dries quickly and packs small. Used for five-panel caps, bucket hats, running caps and the…
WovenRipstopLightweight
- Warmth
- Low
- Breathability
- Moderate
- Stretch
- Low
Cap & Hat Materials
Recycled Polyester Cap Twill
A polyester twill made from recycled plastic bottles. It generally behaves like standard polyester: quick-drying, colour-fast and well suited to sublimation. The recycled share and any…
WovenTwillMidweight
- Warmth
- Low
- Breathability
- High
- Stretch
- Low
Cap & Hat Materials
Polyester Cap Mesh
An open, breathable mesh used for the back panels of trucker caps and the vents of sport caps. It comes in fine or open weaves and…
MeshLightweight
- Breathability
- Very high
- Stretch
- Moderate
Cap & Hat Materials
Wool Blend & Tweed (Cap Fabric)
Wool blended with polyester or acrylic, or woven into tweed and herringbone. Warm, textured and traditional, it is used for flat caps, snapbacks, fitted caps and…
WovenMidweight
- Warmth
- High
- Breathability
- Moderate
- Stretch
- Low
Cap & Hat Materials
Faux Suede
A polyester microfibre with a soft, suede-look surface. It gives cowboy hats, gambler hats, berets and snapbacks a rich, matte look at a lower cost than…
WovenMidweight
- Warmth
- Low
- Breathability
- Moderate
- Stretch
- Low
Cap & Hat Materials
PU Leather-Look
A polyurethane-coated fabric with a leather-look grain. Used for hat bands, cap peaks, patches, flat caps, bomber hats and cowboy hats where a smooth, wipe-clean surface…
WovenMidweight
- Warmth
- Low
- Breathability
- Low
- Stretch
- Low
Cap & Hat Materials
Poly-Cotton Twill (65/35)
A twill woven from a polyester-cotton blend, most often 65% polyester and 35% cotton. It keeps the clean look of cotton twill but usually holds its…
WovenTwillMidweight
- Warmth
- Low
- Breathability
- High
- Stretch
- Low
Cap & Hat Materials
Acrylic/Wool Blend (Snapback Fabric)
A firm woven blend of acrylic with some wool, the classic fabric of flat-peak snapback and fitted caps. Its smooth, slightly felted face holds a structured…
WovenMidweight
- Warmth
- Moderate
- Breathability
- Moderate
- Stretch
- Low
Cap & Hat Materials
Waxed Cotton Canvas
Cotton canvas treated with wax so that it helps shed light rain and wind and slowly takes on a darker, worn patina. It gives five-panel caps,…
WovenCanvasHeavyweight
- Warmth
- Low
- Breathability
- Low
- Stretch
- Low
Cap & Hat Materials
Sherpa (Teddy Fleece)
A polyester fleece with a deep, curly pile that looks like sheep's wool. It is the warm lining of trapper and bomber hats, ear flaps and…
FleeceSherpa (teddy fleece)Heavyweight
- Warmth
- Very high
- Breathability
- Moderate
- Stretch
- Moderate
Cap & Hat Materials
Faux Fur
A long-pile knitted fabric in acrylic or modacrylic, usually on a polyester back, that imitates animal fur. Used for the lining, ear flaps and trims of…
Faux fur (long pile)Heavyweight
- Warmth
- Very high
- Breathability
- Low
- Stretch
- Low
Cap & Hat Materials
Quilted Nylon
A light nylon shell stitched to a layer of polyester wadding in diamond or channel quilting. It gives bomber hats, trapper hats and winter caps a…
QuiltedWovenMidweight
- Warmth
- High
- Breathability
- Low
- Stretch
- Low
Cap & Hat Materials
Linen & Cotton-Linen
Linen woven from flax fibre, on its own or blended with cotton. Light, cool and breathable, with a natural slub texture, it suits summer bucket hats,…
WovenLightweight
- Warmth
- Low
- Breathability
- Very high
- Stretch
- Low
Cap & Hat Materials
Terry Towelling
A cotton fabric covered in soft, uncut loops, like a towel. It absorbs sweat and water and gives retro bucket hats, beach hats and visors a…
Terry loopMidweight
- Warmth
- Moderate
- Breathability
- High
- Stretch
- Low
Cap & Hat Materials
Wool Felt (Hat Body)
Wool fibre pressed into a dense, matte felt that is steamed and shaped into hat bodies. It holds a crown and a brim, and is the…
Felt (non-woven)Midweight
- Warmth
- High
- Breathability
- Moderate
- Stretch
- Low
Cap & Hat Materials
Paper Straw
Paper yarn braided or woven into a light, flexible straw. It is the most common material for Panama-style, beach, floppy and cloche hats, and it can…
Braided or woven strawLightweight
- Breathability
- Very high
- Stretch
- Low
Cap & Hat Materials
Wheat Straw
Natural wheat stems plaited into a light, warm-toned straw. It gives beach, boater-style, cowboy and Panama-style hats a natural look and a light, breathable feel.
Braided or woven strawLightweight
- Breathability
- Very high
- Stretch
- Low
Cap & Hat Materials
Palm Straw
Palm leaf cut into strands and woven into a supple, hard-wearing straw. It is used for Panama-style, beach and floppy hats and stays flexible enough to…
Braided or woven strawLightweight
- Breathability
- Very high
- Stretch
- Low
Cap & Hat Materials
Raffia
A natural palm fibre used as a soft, matte, slightly rustic straw. Braided or crocheted into beach hats, floppy hats and cloche hats, it gives a…
Braided or woven strawLightweight
- Breathability
- Very high
- Stretch
- Low
Cap & Hat Materials
Fur Felt (Hat Body)
Felt made from fine animal fur fibre, usually rabbit or hare, which is denser, smoother and lighter than wool felt. It is the traditional material of…
Felt (non-woven)Midweight
- Warmth
- High
- Breathability
- Moderate
- Stretch
- Low
Cap & Hat Materials
Seagrass Straw
Dried seagrass stems twisted and woven into a sturdy, slightly glossy straw with a green to golden tone. It makes firm sun hats, beach hats and…
Braided or woven strawMidweight
- Breathability
- High
- Stretch
- Low
Cap & Hat Materials
Toquilla Straw (Panama)
The straw of genuine Panama hats, hand-woven in Ecuador from the leaves of the toquilla palm. It is fine, light and flexible, and the finer the…
Braided or woven strawLightweight
- Breathability
- Very high
- Stretch
- Low
Cap & Hat Materials
Cap Buckram & Foam Interlining
The hidden layers that give a cap its shape: stiff buckram or fusible interlining behind the front panels, and a foam layer behind the front of…
Lightweight
Cap & Hat Materials
Cap Sweatband & Lining Fabrics
What touches the head: a cotton, moisture-wicking polyester or terry sweatband, and satin, cotton or quilted linings in hats and uniform caps. They decide comfort, sweat…
Lightweight
- Warmth
- Low
- Breathability
- High
- Stretch
- Moderate
At a glance
Cap and hat materials compared
Typical characteristics relative to the other fabrics in the library.
| Fabric | Construction | Weight class | Warmth | Breathability | Stretch | Moisture management | Typical products |
|---|---|---|---|---|---|---|---|
| Polyester Interlock | Interlock | Midweight | Moderate | High | Moderate | High | Balaclavas, Scarves, Ski wear, Caps & hats |
| Polyester Microfiber Knit | Single jersey, Interlock | Lightweight | Low | High | Moderate | High | Balaclavas, Beanies, Scarves, Ski wear, Caps & hats |
| Stretch Velvet (Knit Velour) | Knit velvet (velour) | Midweight | High | Moderate | Very high | Moderate | Balaclavas, Scarves, Caps & hats |
| Recycled Polyester Knit (RPET) | Single jersey, Interlock | Light to heavy (varies) | Moderate | High | Moderate | High | Balaclavas, Ski wear, Caps & hats |
| Polyester Piqué | Piqué | Midweight | Low | High | Moderate | High | Balaclavas, Caps & hats |
| Polyester Jersey | Single jersey | Lightweight | Low | Very high | Moderate | Very high | Balaclavas, Beanies, Scarves, Ski wear, Caps & hats |
| Polyester/Spandex Stretch Jersey (SHY Series) | Single jersey | Midweight | Moderate | High | Very high | Very high | Balaclavas, Ski wear, Caps & hats |
| Polyester Mesh | Mesh | Lightweight | Low | Very high | Moderate | High | Balaclavas, Ski wear, Caps & hats |
| Bird’s-Eye Mesh | Bird’s-eye mesh | Lightweight | Low | Very high | Moderate | Very high | Balaclavas, Caps & hats |
| 3D Spacer Mesh | 3D spacer mesh | Midweight | Moderate | Very high | Low | High | Balaclavas, Ski wear, Caps & hats |
| Softshell (Bonded Performance Fabric) | Softshell | Heavyweight | High | Moderate | High | Moderate | Balaclavas, Ski wear, Caps & hats |
| Nylon Taslan Shell | Woven, Taslan | Midweight | Low | Moderate | Low | Low | Ski wear, Caps & hats |
| Cotton Twill (Cap Fabric) | Woven, Twill | Midweight | Low | High | Low | Low | Caps & hats |
| Brushed Cotton Twill | Woven, Twill | Midweight | Moderate | High | Low | Low | Caps & hats |
| Cotton Canvas | Woven, Canvas | Heavyweight | Low | Moderate | Low | Low | Caps & hats |
| Denim (Cap Fabric) | Woven, Denim | Midweight | Low | Moderate | Low | Low | Caps & hats |
| Corduroy (Cap Fabric) | Woven, Corduroy (cut pile) | Midweight | Moderate | Moderate | Low | Low | Caps & hats |
| Nylon & Ripstop (Cap Fabric) | Woven, Ripstop | Lightweight | Low | Moderate | Low | Moderate | Caps & hats |
| Recycled Polyester Cap Twill | Woven, Twill | Midweight | Low | High | Low | High | Caps & hats |
| Polyester Cap Mesh | Mesh | Lightweight | – | Very high | Moderate | High | Caps & hats |
| Wool Blend & Tweed (Cap Fabric) | Woven | Midweight | High | Moderate | Low | Moderate | Caps & hats |
| Faux Suede | Woven | Midweight | Low | Moderate | Low | Low | Caps & hats |
| PU Leather-Look | Woven | Midweight | Low | Low | Low | Low | Beanies, Caps & hats |
| Poly-Cotton Twill (65/35) | Woven, Twill | Midweight | Low | High | Low | Moderate | Caps & hats |
| Acrylic/Wool Blend (Snapback Fabric) | Woven | Midweight | Moderate | Moderate | Low | Moderate | Caps & hats |
| Waxed Cotton Canvas | Woven, Canvas | Heavyweight | Low | Low | Low | Low | Caps & hats |
| Sherpa (Teddy Fleece) | Fleece, Sherpa (teddy fleece) | Heavyweight | Very high | Moderate | Moderate | Low | Ski wear, Caps & hats |
| Faux Fur | Faux fur (long pile) | Heavyweight | Very high | Low | Low | Low | Beanies, Ski wear, Caps & hats |
| Quilted Nylon | Quilted, Woven | Midweight | High | Low | Low | Low | Ski wear, Caps & hats |
| Linen & Cotton-Linen | Woven | Lightweight | Low | Very high | Low | High | Caps & hats |
| Terry Towelling | Terry loop | Midweight | Moderate | High | Low | Very high | Caps & hats |
| Wool Felt (Hat Body) | Felt (non-woven) | Midweight | High | Moderate | Low | Moderate | Caps & hats |
| Paper Straw | Braided or woven straw | Lightweight | – | Very high | Low | Low | Caps & hats |
| Wheat Straw | Braided or woven straw | Lightweight | – | Very high | Low | Low | Caps & hats |
| Palm Straw | Braided or woven straw | Lightweight | – | Very high | Low | Low | Caps & hats |
| Raffia | Braided or woven straw | Lightweight | – | Very high | Low | Low | Caps & hats |
| Fur Felt (Hat Body) | Felt (non-woven) | Midweight | High | Moderate | Low | Moderate | Caps & hats |
| Seagrass Straw | Braided or woven straw | Midweight | – | High | Low | Low | Caps & hats |
| Toquilla Straw (Panama) | Braided or woven straw | Lightweight | – | Very high | Low | Low | Caps & hats |
| Cap Buckram & Foam Interlining | Lightweight | – | – | – | – | Caps & hats | |
| Cap Sweatband & Lining Fabrics | Lightweight | Low | High | Moderate | Very high | Caps & hats |
Choosing a material
Which material for which cap or hat
The outer fabric sets the season, the price and how the logo is applied. Structure comes from the interlining, not from the fabric alone.
| Material | Best for | Strengths | Watch out for |
|---|---|---|---|
| Cotton twill | Baseball, dad, six-panel, snapback and fitted caps | Firm, smooth, takes embroidery cleanly | Does not take sublimation; slower to dry |
| Poly-cotton twill | Uniform, promotional and workwear caps | Holds its colour, shrinks less and dries faster than cotton | Sublimation looks faded on the cotton share |
| Acrylic/wool blend | Flat-peak snapback and fitted caps | Holds a structured crown; shows 3D embroidery well | Prints need a test first |
| Canvas, waxed canvas and denim | Bucket hats, five-panel and casual caps | Hard-wearing, textured, ages well; wax sheds light rain | Stiff at first; waxed canvas is wiped clean, not washed |
| Corduroy | Autumn and winter dad caps and flat caps | Soft, warm, textured | Pile can swallow fine logo detail |
| Nylon and ripstop | Five-panel, sport and packable caps | Light, quick-drying, packs small | No sublimation; can feel slippery |
| Recycled polyester | Sport caps and all-over prints | Quick-drying, colour-fast, takes sublimation | Recycled share and certificate come from the supplier |
| Sherpa, faux fur and quilted nylon | Bomber and trapper hats, ear flaps and winter linings | Very warm; quilted nylon is light and wind-resistant | Logos go on the shell, a patch or a label |
| Wool blend, wool felt and fur felt | Flat caps, Homburg, cowboy, top and cloche hats | Warm, holds a shape, premium look; fur felt is the finest | Not printed; needs careful packing |
| Faux suede and PU leather-look | Cowboy hats, berets, trims and bands | Rich matte or smooth look at lower cost | Embroidery needs a tested stitch count |
| Linen and terry towelling | Summer bucket hats, flat caps and beach hats | Linen is cool and breathable; terry is soft and absorbent | Linen creases; terry takes embroidery, not prints |
| Paper, wheat, palm and seagrass straw | Panama-style, beach and floppy hats | Light, breathable, natural look | Creases if packed badly; decorate through the band |
| Toquilla straw | Genuine Panama hats | The finest, lightest straw, hand-woven in Ecuador | Quoted on request; the weave grade sets the price |
Components
What gives a cap its shape and comfort
Two cap models in the same fabric can look and feel very different because of what is inside.
-
Buckram and interlining
Stiff buckram or fusible interlining behind the front panels keeps a structured cap upright. Dad caps and unstructured caps leave it out.
-
Foam front
A foam layer behind the front of a trucker cap gives a smooth, firm surface for embroidery and prints.
-
Sweatbands and linings
Cotton, moisture-wicking and terry bands manage sweat; satin and cotton linings make hats and uniform caps easier to wear.
-
Brim and peak inserts
Stiff plastic or board inserts hold a peak flat or curved, and a fine wire in the edge holds the shape of a hat brim.
Related fabrics
Other fabrics used in caps and hats
These fabrics are also used in caps and hats and are described in full on their main family page.
Polyester Interlock
A double-knit polyester with a smooth, stable face on both sides. It takes sublimation and screen prints cleanly…
Polyester Microfiber Knit
A fine knit made from very thin polyester filaments. It feels smooth and soft, drapes well and shows…
Stretch Velvet (Knit Velour)
A stretchy knit with a short, dense, soft pile on the face, also called knit velvet or velour.…
Recycled Polyester Knit (RPET)
Polyester knitted from recycled feedstock, usually post-consumer PET bottles. It generally performs much like virgin polyester: quick-drying, durable…
Polyester Piqué
A textured knit with a fine raised pattern, best known from polo shirts. The texture breathes well, hides…
Polyester Jersey
A light single-knit polyester with a smooth face. It dries fast, takes sublimation in full colour and is…
Polyester/Spandex Stretch Jersey (SHY Series)
Our SHY series stretch jersey: 88% polyester and 12% spandex, knitted for four-way stretch and recovery. Close-fitting, smooth,…
Polyester Mesh
An open knit with clearly visible holes that lets air straight through. It is used for vents and…
Bird’s-Eye Mesh
A polyester knit with a pattern of tiny holes, named after its bird’s-eye look. It lets air through…
3D Spacer Mesh
Two knitted faces held apart by upright yarns, giving a thick, springy mesh that air flows through. It…
Softshell (Bonded Performance Fabric)
A stretch outer fabric bonded to a soft fleece or knit backing, usually with a water-repellent finish. It…
Nylon Taslan Shell
A nylon woven from air-textured yarn, which gives it a matt, slightly cotton-like face and good abrasion resistance.…
Products
Where these materials are used
In our custom caps and hats, from baseball caps and beanie-style headwear to bucket, beach and cowboy hats.
- Custom caps & hatsCustom caps and hats under your label: baseball, dad, trucker, snapback, bucket, boonie, safari and camo caps. From…
- Custom balaclavasPrivate-label balaclava and ski mask manufacturer in Sialkot, Pakistan. Knitted, fleece, mesh and sublimated styles from 50 pcs,…
- Custom scarvesCustom scarves under your label: knitted, football, silk and printed scarves, bandanas, neckerchiefs and hijabs. From 50 pcs…
- Custom ski wearCustom ski jackets, pants, suits, fleece and base layers under your label, waterproof 5K–20K with taped seams. From…
- Custom beaniesCustom beanies under your label: cuffed and logo, streetwear, pom-pom and winter, sports and jacquard beanies. From 50…
Product pages that use these fabrics:
Journal
Guides on caps and hats
Product Guides & Comparisons · 15 min readDifferent Types of Balaclavas: Styles, Materials and Uses ExplainedThe types of balaclavas explained: face openings, hinged and hooded styles, knitted vs cut-and-sew, materials, uses and fashion styles, with a quick guide.Read the guide 
Product Guides & ComparisonsOne-Hole, Two-Hole, Three-Hole or Open Face? Balaclava Openings ExplainedBalaclava face openings explained: one-hole, two-hole, three-hole and open face compared for breathing, goggles, glasses, helmets, fabrics and uses.Read the guide 
Manufacturing & ProductionKnitted vs Cut-and-Sew Balaclavas: How Each Type Is MadeKnitted vs cut-and-sew balaclavas: how each is made, what “seamless” really means, flatlock seams under helmets, decoration options and how to choose.Read the guide
FAQ
Cap and hat materials: frequently asked questions
Which fabric is best for a baseball cap?
Cotton twill is the standard, because it is firm, smooth and takes embroidery cleanly. Polyester or nylon suits sport and quick-drying ranges, and brushed cotton or canvas gives a softer, washed look.
Can every cap fabric be printed with sublimation?
No. Sublimation works only on polyester, ideally white or light. Cotton, nylon, wool and felt are decorated with embroidery, screen or heat-transfer prints, patches and labels instead.
Do you make genuine Panama hats?
Our Panama-style hats are made in paper, wheat, palm or seagrass straw. Genuine Panama hats are hand-woven from toquilla straw in Ecuador. We do not weave toquilla ourselves, but toquilla hats can be quoted on request, with the weave grade and source confirmed with your quote.
Can you supply recycled or certified fabrics?
Recycled polyester and organic or certified cotton can be sourced on request, subject to availability. Certificates come from the fabric supplier for the order, and we do not claim a certification unless it can be documented.
Material Library
More fabric families and guides
- All fabrics in the Material Library
- Fleece Fabrics
- Cotton Fabrics
- Merino Wool & Wool Blend Fabrics
- Polyester & Recycled Polyester Fabrics
- Acrylic Knits & Yarns
- Performance Fabrics
- Shell & Waterproof Fabrics
- Insulation & Linings
- Sock Yarns & Constructions
- Knitting Yarns
- Scarf Fabrics
- Waterproof & Breathability Ratings Explained
- Fabric Weight & GSM Guide
- Textile Certifications Guide