Cap Size Charts

Head circumference is the only measurement that decides cap size. Every other dimension — crown depth, panel height, visor length — is derived from it.

• Tape position: 1cm above the eyebrow, across the widest part of the forehead, above the ears and around the occipital bump at the back.
• Tension: snug, not tight. The tape should sit flat against the skin without compressing it.
• Unit: record in centimetres to the nearest 0.5cm. Inches convert but lose resolution on the fitted ladder.
• Repeat: measure twice. If the two readings differ by more than 0.5cm, measure a third time and use the median.

Fitted caps have no closure. Every size is a discrete panel-length build, so tolerances are tight (±0.5cm) and stock plans need every size in the ladder.

Size 7 1/4 is the peak of the bell curve for adult men. Programme buys typically weight 7 1/8, 7 1/4 and 7 3/8 at 20–25% each, with the tails at 5–10%.

One-size caps use a closure to cover the adult range. Panel construction is built to a nominal 58cm and stretched or cinched by the closure.

• Snapback: 55–61cm range, 7 plastic snaps at ~1cm intervals.
• Metal buckle (dad hat): 54–62cm range, infinite adjustment inside the strap length.
• Velcro: 54–62cm range, infinite adjustment. Preferred for promo — cheapest closure.
• Elastic fit / flexfit: S/M (55–58cm) and L/XL (58–61cm) — two sizes replace the ladder.

Junior caps target 52–55cm circumference (ages 6–12). Younger children (2–5) sit around 48–52cm and need a dedicated infant/toddler block — junior tooling won't scale down cleanly.

• Junior one-size: 52–55cm range, adjustable closure.
• Youth fitted: 6 1/2 (52cm), 6 5/8 (53cm), 6 3/4 (54cm). Rarely produced — most junior programmes ship one-size.
• Toddler: 46–50cm. Softer buckram grade or unstructured only.
• Decoration scale: logos scaled to 70–75% of adult artwork. Adult tooling on a junior crown reads oversized.

Sizing tolerance on the finished cap is ±0.5cm on the internal circumference. Anything wider and one full size overlaps the next.

• Measure inside: QC measures the internal sweatband circumference laid flat, doubled. External measurement includes seam allowance and lies.
• Post-wash: cotton caps shrink 1–3% after first wash. Fitted caps are cut oversize by that margin.
• Sweatband stretch: PU sweatbands stretch ~2% over the first month of wear. Wool blends stretch ~1%.