5-Panel vs. 6-Panel Hat: A Comparison to Help You Choose

Are you an ecommerce store owner looking to add new custom hats to your collection? By researching different print-on-demand hat options, you’ve likely seen the 5-panel and 6-panel hats. But what’s the main difference between the two, and which should you choose for your dropshipping business? 

In this post, we’ve created a complete comparison of 5-panel vs. 6-panel caps, along with customization options for each, to help you find the answers to these questions. 

5-panel vs 6-panel hat: the main differences

5-panel hat

Construction

The 5-panel hat gets its name from its construction. It’s made of five panels stitched together to form the hat’s crown—two on the sides (one on each side), two at the back, and one larger front panel. The front panel gives the hat a boxy look that’s popular in streetwear and skater fashion. While five-panel caps are more commonly seen with a flat brim, some also feature a curved brim. 

Design/customization possibilities

The 5-panel cap can be customized by adding your designs to various placements, though this may vary from hat to hat. For example, a popular 5-panel cap is the foam trucker style which features mesh material on the side and back panels, allowing customization only on the front panel. To explore the possible design placements for each cap in our catalog, check out the File guidelines. 

Front panel 

The design placement that all five-panel hats offer is front panel customization. This style can be especially advantageous if you’re going for a larger, more prominent custom embroidery design on the front panel, as it doesn’t have any seams or stitching on it. For example, larger patch-like embroidery, brand names, and other typography or graphic designs that require the full print area will look best on a five-panel hat. 

Side panels 

Some 5-panel caps also offer customization on the side panels. This placement is ideal for smaller logos or design elements, providing space for additional details or subtle branding touches.

Source: Urban Outfitters

Back panels 

Similar to the side panels, the back panels can also be customized with minimalist designs to complement the main design on the front panel or stand alone for a sleek and understated look. 

Source: Feature

Best for:

Breathability. With its less structured fit, the 5-panel hat is a lightweight and breathable option.

Casual and streetwear style. If you’re aiming for a more laid-back, relaxed streetwear vibe, the 5-panel cap is a great choice. When designed with trendy slogans or graphics, it adds an edgy touch to any look.

Large designs. The 5-panel cap’s flat front panel allows for large, uninterrupted designs, making it ideal for showcasing your creativity without seams getting in the way.

6-panel hat

Construction

As you’ve probably guessed, the 6-panel cap is made of six panels—two back panels, two side panels, and two front panels. Because the front is constructed from two smaller panels, it features a center seam dividing them. Although the main difference from 5-panel hats is just one extra panel, 6-panel hats offer a different fit. They closely resemble a classic baseball cap, with a more structured fit and a rounded front. Additionally, six-panel hats typically feature a rounded and slightly longer brim compared to five-panel hats. 

Design/customization possibilities

Front panels

Although 6-panel hats have a center seam dividing the front panels, most customization methods allow printing over it without disrupting the overall design. However, keep in mind that the center seam will still be visible if your design includes unfilled areas. If that’s not an issue—great. But if it is, opt for bolder fonts and larger typography designs, and make sure your graphic designs are fully filled. Or choose a smaller design size and place it on one of the front panels for a more minimalistic look. 

Side panels 

The side panel customization for a six-panel cap is no different from that of a five-panel cap. It’s perfect if you’re aiming for subtle designs and want to add small logos, text, or other graphic elements without overwhelming the overall look. 

Source: Pinterest

Back panels 

Similarly, back panel customization is no different from that of the 5-panel cap. The back of the hat is ideal for showcasing your brand name or offering personalization options, such as adding your customer’s initials for a unique touch. 

Source: Pinterest

Best for:

Comfort. Thanks to the additional panel, six-panel hats contour the head more comfortably, offering a snugger fit than five-panel caps. This design improves both practicality and comfort, especially during physical activities, ensuring the hat stays securely in place. 

Sports gear and athleisure wear. The six-panel cap provides a sportier, sleeker style, making it ideal for adding athletic accessories to your store.

Which one to choose?

As you’ve probably gathered by now, the biggest difference between these hats is the number of panels that make up the crown, resulting in distinct visual appearances. While the differences are subtle, they become important when distinguishing between products, especially if hats are a key part of your business. 

Neither of these hats is inherently better than the other. Each has its own unique benefits, and both are practical and stylish. 

To decide which one to add to your online store, consider your target audience’s preferred style and your specific customization needs. If you’re looking for a lightweight, casual option, choose the five-panel cap. However, if a more structured and sporty aesthetic aligns better with your store’s offerings, the six-panel cap is the way to go. And if the choice is still unclear, why not let your customers decide by offering both hat options in your catalog? 

If you’re looking to expand your selection, be sure to check out our list of the 12 best hats for embroidery. Good luck with your designs!