Patrol Cap Insert

thingiverse

Enjoy this 3D printed patrol cap insert designed by me. Below is some information about the product, that I felt was necessary to include in order to provide the best possible experience.After having spent two years in USAF Honor Guard, I had enough experience to be able to come up with a better solution for blocking a patrol cap. Commercially available solutions are expensive, but carry some imperfections discovered first hand. Hand-made blocked hats crafted by talented members of the USAF Honor Guard Family, on the other hand, are made with the wrong assumption that the crown is flat, causing the front part of it to bend down. These hats are also non-washable.Below are the advantages of my solution:-Cost effective design with a fast turnaround time.-Effortless installation and removal, that does not require any hat modification and allows it to be washed.-Breathable and cushioning design, made with flexible and waterproof material.-Geometrically correct shape, which does not distort the original design of the hat.As nothing is perfect in this world, so is my creation. To this moment, I still consider it not to be finalized. Unfortunately, the official patrol cap specifications (https://quicksearch.dla.mil/qsDocDetails.aspx?ident_number=275170) allow a range of dimensional measurements. Thus, it is impossible to create an insert that perfectly matches a particular hat. Instead, I used the provided central value for each dimensional measurement. According to my experience, dimensional accuracy of a hat varies among manufacturers. I have found that hats made by R&B, Inc. are very precise.Additionally, a hat that has been blocked usually feels bigger, due to its material being stretched. The thickness of 1/8” of the insert effectively reduces the internal size by two sizes, which should make the hat feel the right size again.Being aware of the above, please, do not be discouraged in case the offered insert doesn’t meet your expectations. I would be very happy to improve my design based on your feedback, and work with you directly to make an insert that would perfectly match your hat.To start using the insert, orient its inner rounded edge towards the bottom of your hat, and align the middle of the taller side with the seam at the back of the hat.I recommend using double walls and zero infill to make it lighter and softer. Also, adjust the minimum support angle to 61 degrees in order to avoid any support within the hexagonal holes.I am open to any feedback. Thank you!