Difference Between 5 Panel and 6 Panel Hat

Trying to decide between a 5-panel and a 6-panel hat? You're probably looking for something that fits right, looks good, or works well. Maybe you're launching your merch line. Maybe you just want a cool new hat that matches your vibe. Either way, the number of panels actually makes a big difference.

At first glance, these two styles might seem similar, but they’re built differently, they fit differently, and they serve different purposes. One has a flat front, perfect for big, bold designs. The other has a more classic, rounded shape like your favorite baseball cap.

Let’s break it all down, how each hat is made, how it feels, and when to go for one over the other.

Quick Comparison: 5 Panel vs 6 Panel Hat

What’s a 5-Panel Hat?

A 5-panel hat is made from five fabric panels. The front panel is one large piece, which gives it that clean, flat look. The other four panels shape the sides and back.

5-panel hats started as functional workwear. Paperboys and Bike messengers wore them. Even some military teams did. They were lightweight, comfy, and easy to move in. Eventually, skate culture and streetwear brands picked them up, and now they’re everywhere. The flat front makes them a go-to for bold designs and custom logos.

Key Features

• Flat or slightly curved brim

• A low crown that sits closer to your head

• One big front panel, no center seam

• Usually soft and unstructured, made from cotton, nylon, or mesh

Want to see options? Browse our 5-panel collection, great for printing logos and graphics or showing off your brand.

What’s a 6-Panel Hat?

This one is the classic. A 6-panel hat has six fabric pieces forming the crown. The front is made from two panels that meet in the center with a vertical seam, which gives it a rounder, fuller shape.

If you imagine a baseball cap, this is probably what you’re thinking of. The 6-panel design has been around forever, especially in sports. MLB made it famous, and brands like New Era brought it to everyday fashion. It’s got a bit more structure and fits snugly on the head.

Key Features

• Curved crown and front

• More structured feel

• Sits a little higher than a 5-panel

• Great for embroidery, small logos, or patches

Looking for a hat that’s reliable and ready for your team or brand? Check out our 6-panel hats, perfect for custom embroidery or everyday wear.

Construction & Materials

So what really sets these hats apart? It’s how they’re built, and how that affects the way they feel.

Panel Layout

• 5-panel hats have one solid front panel. No seam, no split, just a clean space that’s perfect for printing.

• 6-panel hats have a seam down the middle of the front. That seam gives it a rounder shape, and it works well if you’re doing embroidery instead of printing.

Materials

You’ll find both styles in fabrics like cotton twill, polyester, mesh, or blends. A lot of 6-panel caps use buckram in the front to help them keep their shape.

Buckram: A stiff fabric inside the front panels of a hat that helps it hold shape.
Mesh: Lightweight, breathable fabric, great for summer wear.

Cotton Twill: Durable cotton weave with a soft texture, commonly used in caps.

If sustainability matters to you (and let’s be honest, it should), there are also more eco-friendly materials out there. Here are a few worth looking out for:

• Recycled polyester mesh (made from plastic bottles)

• Organic cotton twill (grown without harsh chemicals)

• Plant-dyed fabrics (for low-impact color)

• Hemp blends (super durable and sustainable)

Design & Print Area

This is where the panel count really comes into play, especially if you’re customizing.

• 5-panel hats give you a flat front with no seams, so your design has space to breathe. Great for big logos, screen printing, or heat transfers.

• 6-panel hats have that middle seam, which might interrupt large graphics. But it’s perfect for centered embroidery or small patches.

In short:

• Want a wide, clean canvas? Go with a 5-panel.

• Planning on embroidery? A 6-panel is probably your best bet.

Use Cases

For Brands & Creators

5-panel hats are super popular in the streetwear scene. The flat front is perfect for bold, attention-grabbing designs. You’ll see them at festivals, pop-up shops, and skate parks.

For Sports & Teams

6-panel hats are everywhere in sports. The snug fit stays put during movement, and the structured crown helps wick sweat and hold shape. You’ll spot them on baseball diamonds, golf courses, and sidelines across the country.

For Everyday Style

Honestly, both styles work in everyday outfits.

• A 5-panel adds edge to a laid-back look, think joggers and sneakers.

• A 6-panel blends right in with jeans and a tee, giving off a clean, sporty vibe.

Still, deciding between structure and slouch? Check out our guide on the difference between structured and unstructured hats.

Style & Care Tips

How to Wear

• Rock a 5-panel with a graphic tee and some joggers for that creative, street-smart look.

• Wear a 6-panel with a polo or hoodie and jeans, clean, athletic, and easygoing.

How to Care

• Don’t toss them in the washer. Spot clean with a damp cloth.

• Keep structured hats on a stand or stuffed with paper so they keep their shape.

• If your 5-panel brim gets bent out of shape, a little steam and gentle pressure can fix it.

Which One’s Best for You?

Here’s a quick breakdown:

Go for a 5-panel if:

• You want a flat front for screen printing

• Your style leans toward creative or streetwear

• You like a lower, closer fit

Go for a 6-panel if:

• You want that classic baseball cap look

• You’re adding embroidery or patches

• You like a structured, more athletic fit

Why Choose Apparelbus for Hats?

At Apparelbus, we help brands, teams, and creatives bring their ideas to life without the hassle. Whether you’re starting a streetwear label or gearing up your whole crew, we’ve got hats that fit your style and your budget.

Here’s why people love shopping with us:

• No order minimums (buy one or a hundred)

• Bulk discounts that grow with your business

• Ready-for-customization blanks from top brands

• Fast U.S. shipping and helpful support

• Sustainable options like recycled mesh and organic cotton

Explore all our wholesale hats and caps, and you’ll find tons of 5-panel and 6-panel options. Still not sure what you need? Our types of hats guide breaks it all down for you.