Crown Panel Construction

Six identical wedge-shaped panels sewn edge-to-edge form a clean dome. Two front panels + two side + two back, meeting at a central top button. Best geometric fit to a human head — the seam lines fall naturally over ear-to-ear and front-to-back axes.

• Front panel: primary decoration surface — flat or 3D-puff embroidery.
• 6 air-vent eyelets (one per panel), always at the panel's centre-top.
• Structured: buckram fused to front two panels; unstructured: no buckram.
• Silhouettes: snapback, dad hat, fitted cap, trucker front, low-profile.

One unbroken front panel + two side + two back panels. Because the front is a single flat piece with no centre seam, it's the best surface for large front prints, embroideries or patches that would otherwise be split by a 6-panel seam.

• Front: full flat panel; ideal for centred artwork and screen print.
• Fit: slightly boxier than 6-panel; sits lower on the forehead.
• Often paired with a flat, unstructured crown for the camp-cap look.
• Silhouettes: camp cap, 5-panel streetwear, running caps.

Any panel count (usually 6) with the buckram omitted. Crown collapses when set down, curves down over the forehead when worn. Combined with a pre-curved brim and metal buckle closure, this is the dad-hat silhouette that has dominated headwear since ~2016.

• Fabric: 100% cotton twill or garment-washed twill for soft feel.
• Buckram: none, or a very light 30gsm mesh for shape memory only.
• Decoration: flat embroidery, small chest-size logo; puff embroidery clashes with the soft crown.
• Fit: low profile, sits down on the head — never boxy.

Sewing sequence is fixed — get it wrong and the panels twist. Pair matching panels first, then join pairs into halves, then close the crown:

1. Join front pair (F-L to F-R) with a taped seam.
2. Join side pair (S-L to S-R) — mirror-image, same seam width.
3. Join back pair (B-L to B-R); leave the back-centre closure gap on snapbacks.
4. Attach front pair to side pair — left half of crown.
5. Attach back pair to side pair — right half of crown.
6. Close the crown top with the top-button.

• Panel count and layout diagram — call out any decorative-panel choice.
• Buckram: grade (light / medium / heavy) or explicitly "none, unstructured".
• Seam finish: taped seam (list tape colour) or piped seam.
• Top button: self-fabric-covered or hardware button.
• Eyelet pattern: 6 stitched eyelets, or laser-perforation for tech caps.