Materials Cutting in action Visor stitching Front and back seam of the crown Embroidery machine Button application Rack of finished product Boxes of finished caps

Block Club’s office is minutes from the former Federal Reserve Bank Building on Delaware Avenue in Buffalo. That building is now the worldwide headquarters for New Era Cap Company. 

Founded in Buffalo in 1920, the company has been a leader in the headwear industry. With nearly a century of manufacturing under its belt, exclusive licensing with Major League Baseball and more recently, deals with the NHL, NBA and NFL, and collaborations with slews of other fashion labels like A Bathing Ape, Maison Kitsuné and Marvel Comics, New Era has become a household name.

Above are some pictures detailing the 22-step process involved in making a New Era 59Fifty cap - a journey that utilizes the hands and eyes of 22 dedicated and loyal employees who all share a serious commitment to quality and craftsmanship.

Click here for more photographs and details on the process.

- PS

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X-Games Go Retro Cool.I love this branding for ESPN’s X-Games 2011. The illustrations are just kooky enough to signify ‘extreme sports’, the color palette is totally out of some 1970’s vintage gear (and works in a fantastic way), and the typographic explorations available after the jump are to die for. By Jordan Metcalf, found on behance.net - Courtney

X-Games Go Retro Cool.
I love this branding for ESPN’s X-Games 2011. The illustrations are just kooky enough to signify ‘extreme sports’, the color palette is totally out of some 1970’s vintage gear (and works in a fantastic way), and the typographic explorations available after the jump are to die for.

By Jordan Metcalf, found on behance.net

- Courtney

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