Method of making a headwear and the headwear thereof

A manufacturing method of manufacturing a headwear, comprising the steps, irrespective of order, of:

• (a) providing a mold including at least two mold parts having first and second molding surfaces which are complementarily profiled to give shape to said headwear;
• (b) shaping a first substrate in the mold resulting in the first substrate having a non-planar profile which matches at least a portion of the profile of the molding surfaces, wherein the portion of the non-planar profile comprises two surfaces interfaced by a bent, wherein the first substrate covers less than all of the molding surfaces;
• (c) shaping a second substrate in mold resulting in the second substrate having a non-planar profile which matches the profile of the molding surfaces;
• (d) overlaying the first substrate on the second substrate and matching their non-planar profile to form a combined substrate;
• (e) placing a third substrate in the mold with the combined substrate, sandwiching the first substrate;
• and
• (f) shaping the third substrate with the combined substrate in the mold resulting in the third substrate having a non-planar profile which matches the profile of the molding surfaces, thereby forming a seamless structure for said headwear, wherein the first substrate has a higher deformation resistance than the second and third substrates, wherein the first substrate is sandwiched between the second and third substrates to function as a supportive skeletal structure therebetween, wherein the first and second substrates include corresponding bents after shaping and the bents are matched when the second substrate overlays the first substrate to form a bent of the combined substrate, and wherein the third substrate is shaped to include a bent that correspond to the bent of the combined substrate.