A Guide to the Best Hat Fabrics (with Pros and Cons)

Different factors go into making hats. While many people pay attention to the types of hats they want, they take hat fabric for granted. The materials you choose impact the construction and proper care of hats. For example, you can’t clean a woolen hat like you would a nylon one. 

Another consideration that makes hat fabric important is functionality. Different materials affect when people wear hats. For instance, winter hats must keep the wearer warm. Therefore, fabrics with insulation are the most suitable. On the other hand, summers have to be light and breathable to keep the wearer protected and comfortable. 

Hat fabric materials fall into three broad categories:

• Natural fabrics – derived from plants or animals 
• Synthetic fabrics – derived from chemical compounds
• Blended fabrics – a combination of natural and synthetic fibers

You can choose from a wide range of fabrics. This post explores the most popular materials used in hat production. We’ll discuss the pros and cons of each option to help you select the best hat fabrics to bring your hat design ideas to life.   

1. Linen

Linen is one of the oldest materials, dating back to ancient Egypt. It is a natural material made from the stalk of the flax plant. It’s a light and airy material suitable for spring and summer hats. 

Linen has thermo-regulating properties. The weave supports airflow through the fabric, allowing heat to escape. It also reflects heat, creating a ‘shading’ effect on hot summer days. 

Linen has moisture-wicking capabilities, too. That means it moves sweat from the body to the fabric’s outer surface and dries quickly, so moisture doesn’t saturate the fabric. 

The advantages of using linen are 

• Durability – flax fibers have low elasticity and become stronger when wet.
• Hypoallergenic – doesn’t cause allergic reactions.
• Antibacterial/anti-fungal – inhibits bacterial growth.
• Sustainability – doesn’t need pesticides and uses less water than cotton.

The downside to linen is that it wrinkles more than other fabrics, and people with sensitive skin may find the fabric irritable. Linen production is also labor-intensive, making it more expensive than cotton. 

2. Wool

Wool is a natural material composed of soft animal fibers from sheep, alpacas, camels, llamas, or angora goats. People associate wool with berets, fedoras, and custom beanies. However, you can also use it to make baseball caps. 

Wool has insulating properties, meaning it traps dry air and warmth. That makes it a suitable material for winter. In the summer, its moisture-wicking capabilities pull excess heat and moisture from your skin, helping you stay cool. 

Other advantages are

• Durability – wool is flexible and can bend 20,000 times without breaking.
• Stain resistant – wool repels liquids and doesn’t soil easily.
• Flame resistant – wool burns slowly and stops when you remove the flame.

The disadvantage of using woolen hat fabric is cost. Wool is a luxury fiber. It takes time and money to nurture animals to grow high-quality wool. Acrylic is a wool alternative that can mimic the characteristics of wool and is cheaper to produce. 

Wool’s absorbency also makes hair brittle. But lining wool hats with satin can prevent dry, fragile hair. 

3. Cotton

Cotton is another ancient textile and the most common hat fabric material. It is a natural fiber sourced from the cotton plant. 

Cotton’s defining characteristic is versatility. For instance, washed cotton is light and airy, which helps regulate body temperature during the summer. 

On the other hand, brushed cotton has fluffy fibers that trap air and improve the fabric’s insulation. Cotton twill is a weave pattern that creates the sturdy fabric used in denim and is suitable all year round. 

Other benefits of using cotton to make headwear include:

• Color retention – accepts dyes well
• Absorbency – holds up to 27 times its weight in moisture
• Hypoallergenic – doesn’t cause allergies 
• Texture – the soft and breathable material that doesn’t cause skin irritation.

Where cotton falls short is durability. It is less durable than linen and synthetic fibers. So, few hats are 100% cotton. Textile manufacturers blend it with polyester to enhance durability and manage cost because pure cotton hat fabric is expensive.

4. Nylon

Nylon refers to a group of chemicals known as polyamides, specifically polyamide 6.6. 

As a textile, nylon is lightweight and elastic, making it a popular fabric when customizing headwear for different head sizes. 

Other advantages are:

• It holds its shape,
• It’s easy to clean,
• It’s cheap,
• It accepts dye.

Nylon’s drawback is its low moisture absorbency. If moisture-wicking is a selling point of your trucker hats, you can line the headbands of caps with cotton or linen.  

5. Buckram

Have you wondered what the brim of fedora hats are made from? It’s buckram.

Buckram is a loose weave, course cotton (think muslin) soaked in wheat starch or glue. When warmed or wetted, the stiff material bends, allowing you to mold your hat into the desired shape. 

Buckram’s characteristics include strength, durability, and water resistance. It supports and strengthens the bill of athletic and classic hats. However, you can make hats of various styles with this fabric.

6. Polyester

Polyester is a staple fabric in modern headwear brands. It is a synthetic material made from petrochemicals known as polymers. 

It’s the fabric of choice for several reasons, including:

• Durability – withstands repetitive movements and holds its shape.
• Insulation – traps warm air released by the body in the fabric.
• Moisture-wicking – absorbs sweat from the skin, leaving it dry and comfortable.
• Color retention – holds various colors.
• Cost-effectiveness – it’s cheaper than natural materials.

The drawback is that polyester fibers are not breathable and can cause allergic reactions or skin discomfort. Manufacturers counter this by blending it with natural fibers like wool, cotton, linen, and bamboo. The most common blend is poly-cotton. The combination creates highly durable and comfortable hats. 

7. Straw

Nothing says summer beach vacation like a straw hat. Straw is a lightweight material derived from various plants, including wheat, jute, bamboo, sisal, seagrass, and more. There are also straw-like synthetic variations. 

Depending on the material you use, this textile exhibits different characteristics. For example, straw is coarse and stiff – great for making sturdy Panama hats, while raffia is more flexible and suitable for rollable/packable floppy beach hats. 

Straw hats are woven (by hand or machine), and the small openings allow for ventilation and cooling during the hot seasons. However, the defining characteristic of straw fabrics is sun protection. Straw hats offer up to UPF 50 (ultraviolet protection factor), depending on how tight the weave is. The tighter the weave, the higher the UV protection.

Closing

As you can see, there’s more to headwear production than design. Fabric plays a key role in how hats look, feel, and function. Therefore, knowing and choosing the best hat fabrics is crucial for hat vendors.

Different fabrics exhibit different qualities. Some are thermoregulating, others have hypoallergenic properties. Some are sturdy and hold shapes, and others are malleable.  

We shared the most common materials and discussed their advantages and disadvantages. Understanding the different hat fabric types empowers you to make informed decisions when placing bulk orders with private-label hat manufacturers like Acme. 

Along with creating the best custom hats, we barcode and bag orders in-house and take the hassle out of delivery with reputable third-party logistic service providers. So contact us if you need custom hats made of high-quality fabrics.