5-panel vs 6-panel hats: What’s the difference? | Printful
September 26, 2025 | by deven.khatri@gmail.com
What is a 6-panel hat?
A 6-panel hat uses six pieces of fabric to form the crown – two at the front, two on the sides, and two at the back. This extra piece gives the hat a rounder overall appearance.
Most designs have a curved brim, which reinforces the cap’s traditional style and makes it more secure. While it works just as well as a 5-panel for casual looks, the 6-panel is especially well-suited for sports and is widely recognized as the classic baseball cap.
Shape and fit
Most 6-panel hats have a rounded crown, created by the way the six pieces come together at the top. This gives the cap its familiar dome-like shape.
This snug design is a big reason why the 6-panel is so popular for sports and outdoor activities, where a hat needs to stay in place. The rounded build enhances comfort during movement, making it functional and reliable.
That said, not all 6-panels are strictly round. Some have a more boxy structure and durable construction, especially when made with stiffer fabrics. This variety makes the 6-panel adaptable for outdoor adventures, everyday wear, and even more fashion-forward styles.
Read also: How to start a hat business
The six panels
A 6-panel cap’s front is divided by a center seam, created by the additional panel at the front. This detail gives the hat a more traditional look.
Many designs use bold text or filled-in artwork so the seam blends into the overall style and creates a statement piece.
The two side panels curve into the crown, rounding out the structured design and contributing to the hat’s snug fit.
The back panels bring the crown together and usually include adjustable straps like a 5-panel hat. Some versions keep the back simple, while others may add small graphics, tiny stitchings of brand names, or subtle personal touches.
Material and printing
Like 5-panels, 6-panel hats often use cotton, polyester, or nylon, but they also come in a wider range of fabrics such as cotton twill, canvas, corduroy, and wool blends.
This variety comes partly from the construction. With more panels and seams, the 6-panel offers greater structure, allowing it to hold its shape in sturdier fabrics. That’s why materials like twill or wool blends are common for this style.
Similarly, 6-panel hats are most often decorated with embroidery or DTF printing.
Read also: Creative embroidery ideas (plus tips for Print on Demand)
5-panel vs 6-panel caps: Main differences
To make the differences between a 5-panel vs 6-panel cap easier to spot, check out the side-by-side breakdown below. The two styles have their unique benefits, so the right choice comes down to your intended use and personal style.
|
5-panel cap |
6-panel cap |
|
|
Style and use |
Linked with streetwear style, skate culture, and casual looks |
Recognized as the classic baseball cap – popular for sports, outdoor activities, and everyday wear |
|
Construction |
Five panels – one large seamless front, two sides, two back |
Six panels – two front with a center seam, two sides, two back |
|
Shape and fit |
Boxy silhouette, flatter crown, sits lower on the head |
Rounded crown, dome-like profile, sitting higher and more snug |
|
Design placement |
Large seamless front panel, ideal for bold graphics, embroidery, or prints |
Embroidered or DTF designs centered across the two front panels |
|
Materials |
Often lighter fabrics like cotton, nylon, or polyester blends |
Wider variety including twill, corduroy, canvas, wool blends, cotton, nylon, and polyester |
When to buy a 5-panel vs a 6-panel hat
The choice between a 5-panel cap and a 6-panel cap comes down to the vibe and look you’re going for. One gives off a sleek, street-ready edge, while the other leans classic and athletic.
Go for a 5-panel hat if you’re into a boxy, fashion-forward look. The large front panel creates a clean surface for bold graphics and custom patches. Often paired with a flat brim, it feels modern and edgy – something you’d see as a statement piece.
Choose a 6-panel cap if you prefer a timeless shape. With its dome-like crown, it has that familiar baseball cap look that never goes out of style. It’s versatile enough for everyday wear, but also feels at home in sports and outdoor adventures.
More hat styles to add to your collection
While 5-panel and 6-panel caps are classics, they’re not the only options. Here are other hat styles with their own unique attributes:
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Bucket hats – A must-have for laid-back looks and outdoor adventures, with a soft crown and wide brim that give them a relaxed fit.
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Beanies – The go-to for colder days, combining warmth with minimalist designs that work across casual and streetwear outfits.
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Visors – No crown, just a bold front panel brim that keeps the sun out while letting your head breathe.
Conclusion
Both the 5-panel hat and the 6-panel cap have their own unique benefits. The first leans sharp and modern, while the second feels more classic.
If you want hats with your own personal touch, make them with Printful. Pick a hat from our Catalog, open our Design Maker, and add your logo, artwork, or text. Whether you choose five or six panels, you can easily create a custom hat that feels uniquely yours.
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