Abstract: A method of sequentially producing a plurality of disposable headdresses in which the edge of the cap fabric has been folded inward around a peripherally extending elastic cord to provide a smooth edge which contacts the wearer, and provides superior adhesion between the elastic cord and the cap fabric by utilizing an elastic cord and fabric which are coated with or made of thermoplastically compatible materials. The elastic cord and fabric are assembled by passing the fabric and the cord through a guide system which turns the fabric side edges down from a horizontal plane to a vertical plane while an edge guide lays the elastic cord under the fabric, and then turns the fabric under the cord to sandwich in the folded edge. Warm air preheaters heat the elastic cord and the fabric before completing the fabric fold around the cord. The folded edges with the cord inside pass between dual heat wheels which physically press the fabric to the cord and also seal the fabric edge to the inside of the crown.

Abstract: A disposable high-walled chef's hat made of paper or like flexible sheet material cut, scored and folded to provide a hat structure or assembly having a flexible crown piece and a head-encircling head band part respectively secured to opposite ends of the wall part of the hat, which wall part is provided with a plurality of closely spaced vertically extending flat pleats. Opposite ends of the pleats are locked against unintentional unfolding thereof and the pleated wall which forms the outer facing of the hat may be internally backed by an inner liner.