Behind the design: The Pursuit of the Perfect Fit

A Pursuit That Never Ends

The phrase “the pursuit of the perfect fit” is something we coined early in our journey. What we quickly realized is that perfection is never a fixed destination. By the time you think you’ve reached it, you’ve already uncovered new ways to improve. That’s why we see it as a continuous pursuit.

The perfect cap, the perfect fit—they’re always evolving, always just out of reach. And it’s that ongoing challenge that drives us forward every day.

What Goes Into Creating the Best-Fitting Caps

For the past 12 years, we have focused on making great-looking products and creating the best-fitting baseball cap. We’ve always prioritized thoughtful design and high-quality manufacturing. Most importantly, we've always tested our caps with real people—our customers.

Our biggest advantage has been having physical stores, where we meet customers face-to-face. When we make changes to our designs, we’re right there to see how our customers respond.

We’ve watched how small changes influence how a cap feels and fits. So what you see today is the result of 12 years of conversations, adjustments, and iteration after iteration.

What Fit Means to Us

Fit is not just about the circumference of your head. Fit is the intersection between the circumference and the panel design of the cap. That includes the height of the cap, the amount of fabric, and how it rests on your head.

A good fit means no excess material and a cap that sits just right—snug, but not tight. The cap is resting comfortably above your ears without pushing them down.

To get this right, we developed four main sizes that work with different head circumferences. Over time, we've taken these four sizes and refined them even further. So, a truly great-fitting cap fits your head and your style.

And yes, style is the second most important aspect of fit. Your personal preferences and how you want the cap to look on you. That might not have anything to do with the shape of your head. In order to achieve this, we have developed different cap shapes: Legacy and Cruz.

These shapes are built on the same fit principles that we have refined over the years, but each shape gives a different look and fit.

Three Key Elements

To sum it up, we think there are three key elements to fit:

1. Circumference—how the cap wraps around your head.

2. Panel design—the shape and structure of the cap itself.

3. Style—your aesthetic and how you want the cap to look on you.

We're still learning, still refining. But today our caps are the result of 12 years of feedback and dedication. I’m so proud of the fit we’ve developed.

— Sebastian Adams, Co-founder of Varsity Headwear