At Yeah Buddy, we don’t do things by half measure. When we set out to create the lightest, most durable, functional, and moisture-wicking running hat in the world, we knew it wouldn’t be easy. But that’s exactly why we’re here—to push the limits of what a performance cap can be.
The R&D Begins
Before we even sketched a single design, our R&D team scoured the globe, (one of my best mates sent me back into the NY Marathon Expo line up last year to line up to collect 5 caps) collecting the best running hats on the market. We looked at caps from legacy sportswear giants, boutique performance brands, and innovative upstarts. If it claimed to be lightweight, sweat-wicking, or built for endurance, we put it under the microscope. We watched countless hours of YouTube videos on runners preferences, listened to the pod casts and asked just about any runner who had stopped on the street. What do you look for in a cap?
What did we find?
- Some hats were ultra-light but lacked durability.
- Others had great sweat management but felt heavy after long runs.
- Many looked sleek but didn’t hold up under real-world conditions—fraying, fading, or failing in wet weather.
1. Some hats were ultra-light but lacked durability.
Lightweight running hats are designed to minimise distractions and reduce strain over long distances however; many prioritised weight savings at the expense of structural integrity.
Strengths:
- Featherlight materials that felt barely there.
- Breathable designs that allowed for great airflow.
- Comfortable fit without unnecessary bulk.
Weaknesses:
- Prone to tearing: Many ultralight hats used thin synthetic blends that couldn’t withstand trail running, pack compression, or repeated washing.
- Brim collapse: Some featured soft, flexible brims that lost shape over time, offering less sun protection and structure.
- Weak stitching: In high-stress areas (such as adjustment straps and seams), the stitching was often too delicate, leading to fraying and breakage.
Key Finding: While ultralight designs reduce weight, they often come at the cost of long-term durability. The challenge is to find a material that remains tough yet weight-efficient.
2. Some Hats Had Great Sweat Management but Felt Heavy After Long Runs
Effective moisture-wicking is critical in a performance running hat. No one wants a cap that soaks up sweat like a sponge or fails to dry quickly, leading to discomfort, overheating, and unnecessary weight gain during a run.
Strengths:
- High-quality moisture-wicking fabrics (like performance polyester and Merino wool) effectively pulled sweat away from the skin.
- Some brands integrated perforated panels or laser-cut vents for better breathability.
- Sweatband technology (built-in or detachable) helped prevent sweat from dripping into the eyes.
Weaknesses:
- Moisture absorption issues: Some materials retained sweat instead of dispersing it, leading to a cap that felt soggy and heavy mid-run.
- Slow drying times: Hats with dense, layered fabrics trapped moisture, making them uncomfortable in high-humidity conditions.
- Sweatband oversaturation: Some designs featured thick, padded sweatbands, which absorbed too much moisture, becoming waterlogged and adding extra weight.
Key Finding: The ideal running hat should wick sweat quickly and effectively, preventing moisture build-up while maintaining its lightweight feel from start to finish.
3. Some Hats Looked Sleek but Didn’t Hold Up in Real-World Conditions
Aesthetic appeal is important—a good running hat should look as sharp at the start line as it does after months of training. However, many hats that appeared sleek and well-designed didn’t hold up under tough conditions like intense sunlight, heavy sweating, rain, or rough handling.
Strengths:
- Minimalist designs with clean lines and modern colourways.
- Sleek performance fabrics that felt premium and soft.
- Custom fit adjustability, with stretch panels or hidden adjustment systems.
Weaknesses:
- Fabric breakdown from UV exposure: Some materials faded quickly or became brittle after repeated sun exposure.
- Dye bleeding & sweat stains: Dark-coloured hats often showed visible salt stains from sweat, and some fabrics bled colour when exposed to heavy perspiration.
- Brim warping in wet conditions: Some hats used materials that absorbed water, causing the brim to become misshapen after exposure to rain or washing.
- Weak structural integrity: Certain caps looked premium but lacked reinforcement, leading to warped panels, loose seams, or sagging over time.
Key Finding: A great running hat shouldn’t just look good on launch day—it should maintain its form, function, and aesthetic appeal for months (if not years) of intense use.
None of them ticked every box.
"If we’re going to build the ultimate running cap, we have to start by understanding what’s already out there—and then make something better in every single way, without compromise." – Leon Hayes, Founder of Yeah Buddy
What We’re Testing
With a lab and real-world approach, we’re testing:
- Weight: Can we create a cap so light you forget you're wearing it?
- Durability: Will it survive ultra marathons, sweat, rain, and brutal sun exposure
- Moisture Management: Can it wick sweat instantly without feeling damp?
- Fit & Feel: Does it sit perfectly without pressure points or movement?
We’re running tests in heat, humidity, and relentless kilometres, putting materials through stress conditions that mimic the toughest race days.
At Yeah Buddy, we believe that every gram, every stitch, and every fibre matters when it comes to performance running gear. Our goal is audacious yet simple: to create the lightest, most durable, functional, and moisture-wicking running hat in the world.
Before we even think about manufacturing, we’ve taken a scientific approach, assembling an R&D team to analyse the best running caps from around the globe. Our mission? To identify strengths, expose weaknesses, and refine the blueprint for the ultimate running cap.
Here’s how we’re approaching this project—not just as a design challenge, but as a series of hypotheses that must be tested and validated.
Hypothesis 1: A Lighter Hat Will Enhance Performance Without Sacrificing Durability
The Problem:
Many runners experience hat fatigue—a subtle but noticeable discomfort when wearing a heavier cap over long distances. Extra weight translates to increased muscle tension in the neck and head, which, over hours of running, contributes to fatigue.
Our Testing Approach:
We are analysing weight distribution across different materials, panel constructions, and brim reinforcement techniques. Some brands strip down weight by using single-layer polyester, while others use nylon mesh for ventilation. But can we find an approach that delivers both weight savings and long-term durability?
Material Candidates for Testing:
- Ultralight ripstop nylon: Strong, tear-resistant, and used in parachutes and ultralight jackets.
- Polyester micro-mesh: Offers ventilation but may compromise structure.
- Bio-based fibres (e.g., Tencel blends): Sustainable and lightweight but less tested in extreme performance conditions.
Hypothesis 2: An Elite Running Hat Must Have Unparalleled Sweat-Wicking and Quick-Dry Capabilities
The Problem:
Many caps claim to be moisture-wicking, but in practice, they either:
- Become saturated quickly, causing discomfort.
- Retain sweat, increasing weight mid-run.
- Fail to evaporate moisture efficiently, leading to overheating.
Our Testing Approach:
We are evaluating hydrophobic vs. hydrophilic fabric blends to determine optimal moisture transport. The best material must wick sweat away from the scalp while spreading it across a surface area large enough for rapid evaporation.
Material Candidates for Testing:
- Polyester with hydrophobic treatment: Common in high-performance sportswear but can feel synthetic.
- Nylon-elastane blends: Offers stretch and moisture-wicking but may not be as breathable.
- Bamboo-charcoal infused fabric: Naturally antibacterial, odour-resistant, and moisture-wicking.
Key R&D Question: Can we engineer a sweatband or fabric treatment that enhances wicking without adding weight or stiffness?
Hypothesis 3: A Running Hat Must Withstand High UV, Sweat, and Rain Exposure Without Breaking Down
The Problem:
Most running hats degrade too quickly under extreme conditions. UV exposure leads to fading and fabric breakdown, while sweat and rain accelerate disintegration of seams and adhesive components.
Our Testing Approach:
We are subjecting materials to accelerated weathering tests—including:
- UV chamber testing (to simulate months of sun exposure in days).
- Salt and sweat immersion tests (to mimic high-humidity conditions).
- Water repellence trials (to assess performance in light rain vs. storms).
Material Candidates for Testing:
- DWR-treated recycled polyester: Repels water but may impact breathability.
- Ultraviolet Protection Factor (UPF) nylon: Offers sun resistance but might be heavier.
- Cordura-lite fabric: High-strength but needs to be tested for comfort.
Key R&D Question: How do we balance durability and a soft-touch, lightweight feel without making compromises?
Hypothesis 4: A Running Hat Should Feel Secure Without Creating Pressure Points or Discomfort
The Problem:
A poorly fitting cap causes headaches, shifting, or discomfort. Many runners adjust their hats mid-run, which disrupts focus. A good running hat must balance fit security with all-day comfort.
Our Testing Approach:
We are prototyping adjustable fit systems, including:
- Seamless construction to reduce chafing.
- Elasticated back panels vs. traditional Velcro straps.
- Low-profile bonded seams for a barely-there feel.
Material Candidates for Testing:
- Four-way stretch panels: For adaptable sizing and flexibility.
- Elasticated bamboo or Merino wool blend: Naturally moisture-wicking and soft on the skin.
- Thermo-moulded EVA foam brim: Lightweight yet maintains its shape.
Key R&D Question: Can we engineer a one-size-fits-most design that is secure, customisable, and pressure-free?
Next Steps: Testing, Refinement, and Prototyping
We are currently running rigorous lab and field tests to determine which materials and designs hold up in real-world conditions. Lachie Stuart is currently in the United States, covering his 58 Marathons challenge in snow, ice, rain, sun, heat and wind. We are working with Lachie to capture his feedback on the performance of our upcoming range and prior decisions.
Over the next phase, we’ll continue early prototyping, working closely with elite and everyday runners to refine the fit, weight, and feel.
What’s Next?
In Part 2, we’ll take you inside the R&D lab, unveiling early prototypes and sharing insights from material stress tests. The journey to creating the world’s best running hat is just getting started.
If you're as obsessed with performance gear as we are, stay tuned—and if you want to be part of the testing crew, hit us up at @yeahbuddyhq