Distinct Kapz approached Interwoven Design Group to design a reimagined baseball cap—one that allows the visor and crown to be separated and reattached seamlessly with magnetic and mechanical connection. The result is the Distinct Kapz modular headwear system, created to retain the comfort and aesthetics of traditional ca29ps while delivering a premium, patentable modular solution. Our design journey spanned discovery and ideation through full technical development and production-ready documentation.
Distinct Kapz: Modular Headwear
What we did
- Design Research
- Prototyping & Material Testing
- Pattern Making & CAD
- Technical Design for Production
- Manufacturing Coordination
Clients / Collaborators
Product Description
Distinct Kapz is a modular headwear system featuring a removable and interchangeable visor and crown that snap together seamlessly using embedded Polymagnets. Designed to look and feel like a traditional cap, the system introduces a premium, patent-pending mechanism that enables effortless reconfiguration, without compromising comfort, fit, or aesthetics. Interwoven collaborated with Distinct Kapz to reimagine cap construction from the inside out, creating a discreet magnetic interface that aligns automatically, locks securely, and integrates seamlessly into standard manufacturing processes.
Design Process
The design process began with deep research into magnetic fastening, cap construction, and manufacturing constraints. Early concepts explored a range of connection strategies, from cleated mechanical systems to fabric-encased magnets. Foam mockups and 3D prints were used to evaluate alignment, security, and feasibility.
CAD Development & Technical Documentation
Precision was essential for manufacturing. Each component was modeled in CAD, with attention to millimeter-level tolerances for the embedded magnets, track geometry, and seam positioning. Two frame variants—one for curved visors, one for flat—were developed to accommodate variations in circumference and fit.
