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5-Panel vs 6-Panel: Confirm the Construction Before Sampling

A reference photo can show the right logo and still show the wrong cap construction. We have seen that happen in real development work.

What should a buyer confirm first?

Confirm the cap construction before the physical sample is made. In one project, a design started as a 6-panel cap and the buyer later asked to compare it with a 5-panel A-frame. In another, a 6-panel mockup was prepared from a brief that also included a 5-panel reference hat.

Two cases that caused the question

Project 1: the original design file specified a 6-panel cap. The buyer later asked to see a 5-panel A-frame as another option and planned to compare the two styles and fits before deciding.

Project 2: a 6-panel mockup was already prepared, but the attached reference hat was a 5-panel. The buyer then clarified that the reference hat was only meant to show the logo, not the hat style.

What to write on a reference brief

  • Target construction: 5-panel, 6-panel or another named shape.
  • What the reference hat is for: fit, crown shape, logo placement, fabric, or overall construction.
  • If two shapes are being compared, keep them as two separate sample directions.

Record note: identifying and commercial details have been removed from the project records.

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