Looking to sell custom hats? Start with a timeless favorite—the baseball cap.
Originally part of traditional baseball uniforms, the baseball cap has become a global icon. From the ballpark to streetwear, it’s now the most popular hat style in the world—versatile, stylish, and always in demand.
Often called dad hats, baseball caps vary in shape, material, panel count, back closures, and more. Each variation offers a unique fit and feel—perfect for customizing to suit your brand’s style and your customers’ preferences.
In this guide, we’ll break down the key types of baseball caps so you can find the best match for your business—whether you’re going for classic or contemporary.
Ready to explore your options? Let’s play ball.
Types of baseball hats by material
Today’s baseball caps come in a wide range of materials designed for comfort, durability, and style.
From cotton and cotton blends to canvas, jersey mesh, wool, acrylic, and moisture-wicking polyesters—modern caps are made with just about every fabric you can think of.
Does that cover nearly everything? Pretty much, yes.
Here’s a breakdown of some key materials commonly used for baseball caps:
- Brushed cotton: This involves brushing cotton repeatedly, imparting a soft and fuzzy texture to the fabric.
- Cotton twill: A common material for a baseball cap, cotton twill offers a slight sheen and a durable texture. It’s lighter compared to brushed cotton.
- Corduroy: Known for its raised parallel ridges, corduroy offers a unique tactile quality, bringing a sophisticated and vintage charm to baseball caps. Favored for casual and semi-formal settings, corduroy caps make a statement with their distinctive texture and refined aesthetic.
- Denim: Well suited for a laid-back style, denim finds its place among baseball caps, merging comfort with a timeless and rugged appeal. The durable nature of denim ensures longevity, and its ability to fade over time adds character.
- Brushed canvas: Increasingly popular, brushed canvas strikes a balance between durability and a soft texture. The brushed finish adds a touch of sophistication, ensuring that the hats feel great and look stylish.
- Wool blend: A classic moisture-wicking material is combined with modern blends to enhance durability, making wool blend baseball caps ideal for various weather conditions.
- Color dyed/fabric dyed: The manufacturing process of fabric-dyed materials results in textiles with a soft, faded, lived-in appearance and feel. Whether it's the gentle fading of colors or the vintage look achieved through fabric dyeing, these caps exude a laid-back charm that complements any casual outfit.
- Polyester mesh: Often used in the back panels of trucker hats, polyester mesh makes the hat breathable.
When deciding on the fabric of your baseball cap, consider your brand vision. Whether it's the timeless appeal of denim, the sophisticated touch of corduroy, or the modern blend of wool, select the material that resonates with your aesthetic.
Types of baseball hats by shape
As you’ve probably noticed, baseball hats come in various forms and styles. The two primary categories are structured and unstructured shapes, each offering distinct characteristics.
Structured caps
Structured caps feature a supportive material called buckram, positioned between the front two panels to help the hat retain its shape—even after wear or pressure. Originally popularized by baseball players, structured caps now come in a variety of colors, fabrics, and styles.
A great example is the Structured Twill Cap, which pairs a clean 6-panel design with a closed back. With their crisp silhouette and lasting structure, these caps bring timeless style and durability to any wardrobe or product line.
Unstructured caps
Unstructured caps use softer, more flexible fabrics and lack internal support, especially in the front panels. When set down, they tend to collapse or “flop,” creating a laid-back, casual vibe.
If that relaxed style speaks to you, check out our Dad Hat—made from 100% chino cotton twill, trendy and stylish.
In contrast, structured caps include a firm material called buckram in the front panels. This added support helps the cap retain its shape even when not worn, giving it a more polished and defined silhouette. Our Structured Twill Cap is a standout example, combining a classic 6-panel shape with a comfortable snapback fit and plenty of space for custom embroidery.
Which one should you choose?
If you’re going for a sharp, clean profile—structured caps are the way to go. Prefer something softer and more relaxed? Unstructured caps deliver casual comfort and versatility.
Both styles can be customized with embroidery and appeal to different tastes. Consider offering both structured and unstructured options to give your customers the freedom to choose what fits their style best.
Types of baseball hats by back closure
If adjustability matters to you, take note of the closure type—some baseball caps aren’t adjustable.
Let’s take a closer look at a few main ones:
Metal buckle
Utilizing a simple metal push-down/pull-up buckle mechanism, metal buckle closures provide a classic look and allow for easy adjustment. Often, these hats feature a leather strap held in place by the buckle, contributing to a timeless aesthetic and making it easy to dress up or dress down.
Here's a list of hats with metal buckle available at Arc Diverse:
Snapback
Renowned for its adjustable strap at the back, typically made of plastic with snap buttons, a snapback offers a customizable fit. Originating from hip-hop and urban fashion, snapbacks gained popularity for their flat brim and embroidered logos, becoming a symbol of street style.
Here's what Arc Diverse has to offer:
Closed-back
Also known as one-size hats, caps with closed-back closures can’t be adjusted and hats must be purchased in the correct size for the best fit. This fitted cap offers a sleek and fitted appearance, more popular for fashion rather than sports.
These are the options Arc Diverse currently has:
Types of baseball hats by panel count
Baseball hats are constructed from panels—individual pieces of fabric stitched together to form the crown of the hat. The number of panels, often five to seven, is a crucial characteristic influencing the hat’s design and functionality.
5-panel caps
Known for its distinctive construction, the 5-panel cap (or camp cap) features a single front panel and a shallow, streamlined crown. This flat, uninterrupted surface makes it an ideal choice for screen printing or custom embroidery, offering a clean canvas for your designs.
Originally rooted in 1980s skate culture and adopted by Brooklyn’s streetwear scene, the 5-panel cap has evolved into a versatile staple. Whether you’re a surfer, skater, or city dweller, its laid-back silhouette adds a casual yet stylish edge to any outfit.
Unlike other caps, the 5-panel wears bold patterns and all-over prints with ease—without looking overdone.
6-panel caps
The 6-panel cap, distinguished by its crown divided by a seam down the middle, brings a sporty and structured aesthetic to the table. With six triangular panels sewn together, these caps offer a wider brim than their 5-panel counterparts. While not recommended for screen printing due to the central seam, the 6-panel design allows customization with embroidery.
While most 6-panel caps feature panels of the same color, consider customization options with different-colored panels for a personalized touch.
7-panel caps
The 7-panel hat combines the best features of 5 and 6-panel caps. The crown consists of six triangular fabric pieces reminiscent of the 6-panel style, with an additional larger front panel. This larger front panel provides an uninterrupted canvas for designs and logos, adding to the cap’s visual appeal.
This makes 7-panel caps an excellent choice for showcasing logos and graphics. Enjoy a balanced structure that combines the wider brim of a 6-panel cap with the design advantages of a 5-panel hat.
The choice between 5, 6, or 7-panel baseball caps extends beyond mere aesthetics, delving into personal expression and practicality. Each style has distinctive characteristics, catering to different tastes and fashion preferences. Whether you opt for the simplicity and versatility of a 5-panel cap, the sporty appeal of a 6-panel design, or the best-of-both-worlds structure of a 7-panel hat, understanding these distinctions allows you to make a statement with your headwear designs.
Which Dad Hat Are You Rocking?
From brushed cotton classics to bold 7-panel styles, today’s dad hats are more than just a trend—they’re a reflection of personality, purpose, and style.
Whether you’re drawn to the crisp structure of a 6-panel cap, the laid-back softness of an unstructured chino cotton hat, or the streetwise edge of a snapback, there’s a perfect fit waiting for you. Prefer breathable comfort? Try mesh-backed trucker caps. Want something timeless? Go for a metal buckle closure with a leather strap. Feeling creative? A 5-panel cap offers the perfect canvas for bold prints or embroidery.
At Arc Diverse, we carry a wide range of custom-ready hats to suit every mood, brand, or vibe. No matter how you wear it, your choice of dad hat says something unique about you.
So—which one are you rocking?