A patented packable cap, from sketch to production

The brief was a cap you could fold into a pocket and still wear the next day: durable, lightweight, washable, and packable without losing its shape — a combination the founder had patented but never manufactured.

We worked alongside their industrial design team from the first sketches, translating the patent into something a sewing line could actually build repeatably. The crown structure and the fold behaviour were the hard part; each sample round tested a different combination of panel construction and fabric weight until the cap returned to shape after being crushed, not just after being folded neatly.

Production runs in Bangladesh, on the same headwear lines that make our own label.

Why this one matters

It is the argument for starting small, proven end to end: a founder with a drawing and a patent, and a finished product on a shelf inside two quarters. That is the same path our First Run programme is built around.