MIL-DTL-20268J.pdf

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INCH-POUND

MIL-DTL-20268J

18 February 2025

SUPERSEDING

MIL-DTL-20268H(MC)

13 February 2017

DETAIL SPECIFICATION

FRAME, CAP

This specification is approved for use by all Departments and Agencies of the Department of Defense.

1. SCOPE

1.1 Scope. This specification covers service and dress cap frames.

1.2 Classification. The cap frames are of the following types, classes, and sizes, as specified (see 6.2):

1.2.1 Types and classes.

a. Type I – Black poromeric visor

(1) Class 1 – with black poromeric chin strap

(2) Class 2 – with gold chin strap

b. Type II – Black broadcloth visor

(1) Class 1 – with field grade embroidery and gold chin strap

(2) Class 2 – with field grade embroidery and black poromeric chin strap

(3) Class 3 – with general officer embroidery and gold chin strap

(4) Class 4 – with general officer embroidery and black poromeric chin strap

1.2.2 Sizes. The frame caps are of the following sizes. The recommended head measurements for each size are listed in 3.6.

Schedule of sizes

6 6-5/8 7-1/4

6-1/8 6-3/4 7-3/8

6-1/4 6-7/8 7-1/2

6-3/8 7 7-5/8

6-1/2 7-1/8 7-3/4

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2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

COMMERCIAL ITEM DESCRIPTIONS

A-A-50199 - Thread, Polyester Core, Cotton or Polyester-Covered

A-A-52094 - Thread, Cotton

A-A-59826 - Thread, Nylon

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-B-3461 - Button, Insignia, Metal, Uniform and Cap

MIL-E-17568 - Embroidery Materials, Metallic and Synthetic Metallic

MIL-DTL-20271 - Lace, Gold - Ornamental

MIL-DTL-29405 - Cloth, Broadcloth: Wool and Wool/Nylon

MIL-DTL-32075 - Label: For Clothing, Equipage, and Tentage, (General Use)

(Copies of these documents are available online at https://quicksearch.dla.mil/.)

2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

AMERICAN SOCIETY FOR QUALITY (ASQ)

ASQ/ANSI Z1.4 - Sampling Procedures and Tables for Inspection by Attributes

(Copies of this document are available online at https://asq.org.)

ASTM INTERNATIONAL

ASTM D256 - Standard Test Methods for Determining the Izod Pendulum Impact Resistance of Plastics

ASTM D638 - Standard Test Method for Tensile Properties of Plastics

ASTM D790 - Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials

ASTM D792 - Standard Test Methods for Density and Specific Gravity (Relative Density) of Plastics by Displacement

ASTM D1238 - Standard Test Method for Melt Flow Rates of Thermoplastics by Extrusion Plastometer

ASTM D1525 - Standard Test Method for Vicat Softening Temperature of Plastics

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ASTM D1593 - Standard Specification for Nonrigid Vinyl Chloride Plastic Film and Sheeting

ASTM D2240 - Standard Test Method for Rubber Property–Durometer Hardness

ASTM D2821 - Standard Test Method for Measuring the Relative Stiffness of Leather by Means of a Torsional Wire Apparatus

ASTM D4976 - Standard Specification for Polyethylene Plastics Molding and Extrusion Materials

ASTM D6075 - Standard Test Method for Cracking Resistance of Leather

ASTM D6193 - Standard Practice for Stitches and Seams

ASTM E1282 - Standard Guide for Specifying the Chemical Compositions and Selecting Sampling Practices and Quantitative Analysis Methods for Metals, Ores, and Related Materials

(Copies of these documents are available online at www.astm.org.)

2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 First article. When specified (see 6.2), a sample shall be subjected to first article inspection in accordance with 4.2.

3.2 Recycled, recovered, environmentally preferable, or biobased materials. Recycled, recovered, environmentally preferable, or biobased materials should be used to the maximum extent possible, provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life cycle costs.

3.3 Design. The caps shall be the Marine Corps designs specified in figures 1 through 8, consisting of a circular inner headband, with crescent shaped, embroidered cloth or poromeric top visor centered at the front of the frame. The visors shall be properly molded with heat into the uniform crescent shape and shall be the same size for all sizes of frame. The set of the visor from the horizontal plane of the headband shall not be more than 35 degrees or less than 30 degrees. The visor shall be flanged outward and set so that the stitching does not touch the forehead.

The lapped ends of the inner band shall be lapped 1±1/4 inch to the right or left of the center back, and fastened together with not less than two staples. The sweatband shall not be visible at the lower edge of the headband. The support, support holder, and adjustable steel wire grommet shall conform in all respects to the design, dimensions, and details specified in figures 2 and 3 and as specified herein. The crown support stay holder shall be vertically straight, flush, and secure against the headband. Each cap frame shall have a chin strap attached to the cap with two insignia buttons inserted through the lower sides of the headband into their respective screw tubes and securely attached. A hole shall be punched through the left and right sides of the headband to allow for the button screw tubes. The holes shall be positioned so that the center of the screw tube on both sides of the finished frame shall be 5-3/4±1/16 inches from center of visor and 5/8±1/16 inch from the lower edge of headband. Each frame shall be supplied with a clear acetate crown protector (see 3.4.12).

3.4 Materials.

3.4.1 Inner band. The inner band shall be of a high density (linear) polyethylene plastic material, in black shade, conforming to group 2, high density class 3 or 4, grades 1 or 2, of ASTM D4976, except that the low temperature brittleness, dielectric constant, dissipation factor, and thermal stress cracking resistance requirements shall not be applicable. The band material shall be extruded, stripped, slit, or cut 2-1/4±1/16 inches in width and 0.030±0.002 inch in thickness. Testing shall be as specified in 4.4.

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3.4.1.1 Stiffness. The inner band material shall have a stiffness (scale reading) between 11 and 27 inclusive when tested as specified in 4.4.1.

3.4.1.2 Bending. The inner band material shall show no evidence of cracks after the bending test specified in 4.4.2.

3.4.2 Headband outer covering. The headband outer covering shall be made from a commercially available gabardine, 100 percent polyester, 6.8 ounce per square yard, shade black. As an alternate, 6.0-ounce wool-synthetic broadcloth in a black shade may be used. The cloth shall be cut 3-3/4±1/8 inches wide in the warp or filling direction and cut to the proper length to snugly fit around the headband.

3.4.3 Sweatband. The sweatband shall be made from artificial leather composed of a nonwoven synthetic substrate impregnated with an elastomeric binder. The top surface of the substrate shall be coated with an abrasive resistant finish. The sweatband shall finish 1-7/8±1/16 inches in width. The sweatband shall be dyed black.

3.4.3.1 Sweatband seam reinforcement. The seam joining the ends of the sweatband shall be reinforced with a 5/8- to 3/4-inch wide strip of black pyroxylin coated cotton fabric cut the width of the sweatband, or the plastic film cited in 3.4.3.2 may be used.

3.4.3.2 Plastic film. The plastic film for the sweatband shall be 0.010 inch (nominal) in thickness, conforming to type I of ASTM D1593. The plastic film shall be cut 5/8 to 3/4 inch wide and the full length of the sweatband;

the color shall be black.

3.4.4 Visor. The visor shall be of one size only. The overall width of the visor, before assembly, at center, shall be 2-5/8±1/8 inches. The depth of arc, at center of back edge, shall be 2-7/8±1/8 inches. The width of the visor, after assembly, at center from front edge to lower edge of band shall be 2-1/4±1/8 inches. The distance from the left tip to right tip of visor before assembly, when spread flat shall be 8±1/8 inches. The distance from left tip to right tip after assembly, at lower edge of headband, shall be 11±1/4 inches. The visor shall be constructed from the materials specified in 3.4.4.1 through 3.4.4.2.

3.4.4.1 Type I. The type I visors shall consist of a top ply, bottom ply, and reinforcement plumper paper, bonded together, with binding over the edge (see figure 1, type I). As an alternate to the plumper paper, polyethylene interlining with a gauge of approximately 0.050 inch may be used. The visor shall be constructed by laminating the top ply of poromeric material to the plumper paper and the bottom leather ply with the adhesive specified in 3.4.5.

3.4.4.1.1 Top ply. The top ply shall be smooth, high-gloss poromeric material 0.045±0.003 inch thick, 16-1/2±1 ounces per square yard.

3.4.4.1.2 Bottom ply. The bottom ply shall be of reconstituted leather in a black pebbled gloss finish and shall be 6 to 6-1/2 ounces thick. As an alternate, artificial leather coated with an abrasive resistant finish with a nominal thickness of 0.040 inch may be used, or 0.050 gauge polyethylene conforming to the properties in table I.

TABLE I. Polyethylene properties.

Properties Reference paragraph Requirement

Density, grams per cubic centimeter (g/cm3) 4.3.1 0.944 – 0.976 Melt index, I-2, grams in 10 minutes 4.3.1 0.36 – 0.44 Flexural modulus, pounds per square inch (psi) 4.3.1 153,000 – 187,000 Tensile yield strength, psi 4.3.1 4,050 – 4,950 IZOD impact strength (notched), foot-pounds of force per foot (ft·lbf/ft)

4.3.1 1.08 – 1.32

Vicat softening point, °F 4.3.1 249 – 275 Hardness Shore D 4.3.1 67 – 81

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3.4.4.1.3 Plumper paper. The plumper paper for laminating to the top and bottom plies of the visor shall be 20 gauge and treated so that it retains its original shape after being subjected to immersion test. Plumper paper is not required if the bottom ply is constructed from the 0.050 gauge polyethylene listed as an alternate in 3.4.4.1.2.

3.4.4.2 Type II. The type II visors shall consist of a top ply of black broadcloth conforming to type I of MIL-DTL-29405 and a bottom ply of reconstituted leather or artificial leather in hatters green or black pin seal gloss finish. The visor shall be constructed by laminating the top ply of wool broadcloth to the reinforcement piece of cloth cotton twill face side up with the adhesive specified in 3.4.5. The top ply shall be embroidered with tarnish resistant synthetic gold yarn conforming to type III, class 8 of MIL-E-17568. The design of the embroidery shall be as shown in figure 1 for the appropriate class.

3.4.5 Adhesive. The adhesive shall be used to cement the component parts of the visor together. The adhesive shall be either natural or synthetic rubber cement. Lamination strength shall be a minimum of 5 pounds per inch.

3.4.6 Binding. The binding for the visor edge shall be made from a plastic film, weighing not less than 12 ounces per square yard, and having a thickness of not less than 0.0013 inch. The binding shall be cut 3/4 to 7/8 inch wide in the appropriate length to fully bind the outside edge of the visor. The binding shall be stitched around the outside edge of both type I and II visors and shall finish on top of the visor 3/16 to 1/4 inch wide. The plastic film shall have a smooth high finish, and the color shall match that of the top piece for the visor. The binding shall not crack and shall show no evidence of tackiness. The binding shall be tested as specified in 4.3.1.

3.4.7 Support stay and holder. The support stay and holder shall be stamped from straight chromium stainless steel, commercially designated as type 430 stainless steel with material composition as shown below when tested as specified in 4.3.1. The support, and support holder, shall conform in all respects to the design, dimensions, and details shown in figure 2 and as specified herein.

Composition: Carbon 0.12% maximum (ladle analysis [L.A.])

Manganese 1.00% maximum (L.A.)

Silicon 1.00% maximum (L.A.)

Chromium 14.00% to 18.00% (L.A.)

Phosphorus 0.040% maximum (L.A.)

Sulphur 0.030% maximum (L.A.)

(Remainder iron and constituents)

3.4.8 Buttons. The screwpost button shall be 27-ligne conforming to MIL-B-3461 and as specified in table II.

The button screw tube shall be 1/4 inch in length.

TABLE II. Buttons.

Cap Button

Type I, classes 1 and 2 Type II, style 3, class A, subclass 1, gold

Type II, classes 1 and 3 Type II, classes 2 and 4 Type II, style 3, class B, subclass 1, black

3.4.8.1 Washers. The tinnerman lock washers for securing the screw tube to the frame shall be of spring steel with internal locking flanges to grip the screw tube. As an alternate, heavy duty wire staples may be used to secure the screw tubes.

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3.4.9 Grommet. The grommet wire shall be high grade spring steel, 5/16 inch wide, 0.020±0.002 inch thick, with a white pyroxylin coating not less than 0.003 inch thick. See figure 3 for assembled view. The grommet wire shall be cut as follows:

30-1/4 inches long for sizes 6, 6-1/8, and 6-1/4;

32-1/4 inches long for sizes 6-3/8, 6-1/2, 6-5/8, and 6-3/4;

33-3/4 inches long for sizes 6-7/8, 7, 7-1/8, and 7-1/4; and 35-1/2 inches long for sizes 7-3/8, 7-1/2, 7-5/8, and 7-3/4.

3.4.9.1 Clamp. The adjustment clamp clinched to one end of the steel grommet wire shall be made of the following materials:

Base and clamp - Carbon steel American Iron and Steel Institute (AISI) 1020, hardness Rockwell B scale 66, thickness 0.031±0.002 inch.

Assembled clamp - Electroplated with zinc 0.00005-inch minimum thickness, chrome plated finish.

The clamp assembly shall be approximately 1 inch long and its design shall conform to figure 4. The width of the base component shall be sufficient to accommodate the width of the grommet wire. Testing shall be performed as specified in 4.3.1. Alternate clamps of the same or greater holding power of the grommet wire may be used.

3.4.10 Rivets. The rivets for securing the grommet to the support stay shall be nickel brass, with a head measuring 3/32 inch (minimum) in diameter, when tested as specified in 4.3.1. The length of the rivets shall be sufficient to provide a roll over edge of 0.045 inch to 0.050 inch. Steel rivets of alternative sizes and lengths may be used to attach the grommet wire providing the head of the rivet does not exceed 0.040 inch and the rolled-over edge presents a smooth clinch with no more than three splits in the coil.

3.4.11 Staples. The staples shall be stamped from a heavy-duty corrosion-resistant flat steel wire 0.0250±0.005 inch in thickness, and shall be of sufficient length to thoroughly secure the applicable component parts and leave a smooth flat clinch without any distortion of the materials. The staples shall have a corrosion-resistant finish that shows no evidence of corrosion during the life of the item, or shall be made of a stainless steel.

3.4.12 Crown protector. Each cap frame shall be furnished with a crown protector for the cap cover. The crown protector shall be made of clear, colorless acetate sheeting 0.008±0.001 inch thick and shall be oval shaped, measuring 10 inches by 9-1/2±1/8 inches.

3.4.13 Thread.

3.4.13.1 Thread, cotton. The cotton thread for seaming and stitching the cap frame shall conform to type III, 3-ply, ticket No. A; type III, 3-ply, ticket Nos. A and 00; and type II, 4-ply, ticket No. 24, of A-A-52094. The color of the thread shall be vat dyed black AA. The dyed thread shall show good colorfastness to laundering, perspiration, wet-dry cleaning, and light. Thread, polyester, cotton-covered, size 50, conforming to A-A-50199 may be used.

3.4.13.2 Thread, nylon. The nylon thread for seaming and stitching the cap frame shall conform to type II, size 3, 3-ply, of A-A-59826. The color of the thread shall be vat dyed black AA. The dyed thread shall show good colorfastness to wet-dry cleaning and perspiration.

3.4.13.3 Tarnish-resistant. The thread for embroidering the visors on the type II caps shall be tarnish resistant synthetic gold yarn conforming to type III, class 8 of MIL-E-17568.

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3.4.14 Chin straps.

3.4.14.1 Black chin straps. The black chin straps for the type I, class 1 and type II, classes 2 and 4 caps shall be made of a single ply of poromeric material specified in 3.4.4.1.1. Chin straps shall be made in two sections with a hole at one end and a loop at the other end of each section. Ends of the loop shall be lapped and fastened with two staples through the end of the loops only. A centered, 3/16-inch diameter hole shall be punched into the strap, 3/8 inch from the rounded end of each strap. The top and bottom edges of the strap and the point of the loop shall have an embossed line. All edges shall be stained black. The chin strap design shall be in accordance with the requirements specified in figure 5 which specifies dimensions and construction requirements.

3.4.14.2 Gold chin straps. The gold chin straps for the type I, class 2 and type II, classes 1 and 3 shall be gold laced conforming to class I of MIL-DTL-20271, 5/8 inch wide, constructed with tarnish resistant synthetic yarn conforming to type III, class 8 of MIL-E-17568. The gold lace shall be mounted on leather or other leather-like material to provide body to the strap. Chin straps shall be made in two sections with an eyelet at one end and a loop at the other end of each section. A 3/16-inch inside diameter eyelet shall be inserted through the ends of each strap, opposite the loop end, with the center of the eyelet finishing 3/8 inch from the pointed end. The chin strap design shall be in accordance with the requirements specified in figure 5 which specifies dimensions and construction requirements.

3.4.15 Labels. Each cap shall have a cloth combination identification-size label and a label tag, conforming to

3.4.15.1 and 3.4.15.2.

3.4.15.1 Identification-size label. The combination identification-size label shall conform to type VI, class 4 of MIL-DTL-32075. The label shall bear the following inscription:

NOMENCLATURE: FRAME, CAP

CONTRACT NO.: SPE1C1-00-0-0000 (Example) STOCK NO.: 8405-00-000-0000 (Example) SIZE: 7 (Example)

NAME OF CONTRACTOR

3.4.15.2 Label tag. Each item shall be individually bar-coded with a paper tag for personal clothing items. The paper used for the tags shall conform to type VIII, class 17 of MIL-DTL-32075. The tags shall be located so that they are completely visible on the item when it is packaged as specified (see 5.1). The label’s location and attachment shall cause no damage to the item.

3.5 Patterns. When specified (see 6.2), the patterns for cutting all parts of the cap frame shall be furnished by the contractor and shall be of the proper proportions to provide good fitting cap frames conforming to the finished dimensions in table III. The patterns shall conform to the constructional requirements specified in 3.7 and to the design requirements specified in 3.3.

3.6 Dimensions. The finished frame shall conform to the size and head measurements specified in table III.

The head measurement shall be the inside circumference of the headband at the lower edge of the sweatband. The head measurement of each size frame shall be as specified in table III.

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TABLE III. Head measurements.

Size of frame Head measurements (circumference) 1/

(inches) (cm)

6 19 48 6-1/8 19-3/8 49 6-1/4 19-3/4 50 6-3/8 20-1/8 51 6-1/2 20-1/2 52 6-5/8 20-7/8 53 6-3/4 21-1/4 54 6-7/8 21-5/8 55

7 22 56 7-1/8 22-3/8 57 7-1/4 22-3/4 58 7-3/8 23-1/8 59 7-1/2 23-1/2 60 7-5/8 23-7/8 61 7-3/4 24-1/4 62

NOTE:

1/ All head measurements ±1/8 inch (3.2 mm).

3.7 Construction.

3.7.1 Manufacturing requirements. The frames shall be manufactured in accordance with the operations and the stitch, seam, and stitching types specified in table IV.

3.7.1.1 Stitches, seams, and stitching. All stitching shall conform to ASTM D6193. The frames shall be constructed in accordance with the stitch types and stitches per inch specified in table IV.

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TABLE IV. Stitching.

Operation Stitch type Seam/stitch type Stitches per inch

Topstitch, single needle stitch, or straight stitch:

Construct visor BSb-1 6-9 Construct poromeric chin strap SSa-2 8-10 Construct gold chin strap SSa-1 6-10

Construct headband outer covering:

Fold lengthwise and stitch 1/16 inch from fold forming welt 2±1/16 inch from top edge of finished cover

Osf-1 10-14

Join ends with 3/8-inch seam SSa-1 10-14 Attach headband outer covering to inner headband

SSa-1 6-10

Attach sweatband to band EFd-1 6-10 Attach visor to frame LSa-1 4-8

Overedge:

Serge top and bottom edge of headband outer cover

503 or 504 Efd-1 8-12

Zig Zag:

Construct sweatband assembly:

Stitch plastic welt strip (folded in half lengthwise) to sweatband;

edge of sweatband shall extend 1/16 inch to 1/8 inch from turned edge of strip.

FSb-1 10-14

Join ends and attach reinforcement

FSe-1 10-14

Form loop around gold chin strap and attach to create loop

Hand 4-6

Visor embroidery (as applicable) Hand

3.7.1.2 Tacking and backstitching. Ends of seams and rows of stitching with 301 type stitch, when not caught in other seams or stitching, shall be securely backstitched not less than 1/4 inch. Thread breaks (all stitch types) shall be secured by stitching back of the break not less than 1/2 inch. Skipped stitches and thread breaks may be repaired using stitch type 301 backstitched not less than 1/2 inch on each side of skip or break.

3.7.1.3 Overedge stitching. Overedge stitching shall be done on serging machines with the knife attachment(s) properly set to trim the raveled edge without cutting the material.

3.8 Workmanship. The finished frame shall conform to the quality and grade of product established by this specification. It shall be free from any irregular defects that can adversely affect usage or durability, defects that adversely affect form, fit, or function, and those defects specified in 4.3.2.1.

3.9 Figures. Figures 1 through 6 specify requirements for the frame and the frame’s components. Figures 7 and 8 are furnished for information purposes only. To the extent of any inconsistencies between the written specification and the figures, the written specification shall govern.

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4. VERIFICATION

4.1 Classification of inspections. The inspection requirements specified herein are classified as follows:

a. First article inspection (see 4.2).

b. Conformance inspection (see 4.3).

4.2 First article inspection. First article inspection shall be performed on the cap frame when a first article sample is required (see 3.1). This inspection shall include conformance to the dimensions specified in 3.6, the examination of defects specified in 4.3.2.1, and the tests in 4.4.1 and 4.4.2.

4.3 Conformance inspection. Conformance inspection shall include conformance to the dimensions specified in 3.6, the examination of defects specified in 4.3.2.1, and the tests of 4.4.1 and 4.4.2. Unless otherwise specified (see 6.2), sampling for inspection shall be performed in accordance with ASQ/ANSI Z1.4.

4.3.1 Testing of components. Components and materials in table V shall be tested in accordance with all the requirements of referenced specifications, figures, and standards unless otherwise excluded, amended, or modified in this specification or applicable purchase document. In addition to testing provisions contained in subsidiary specifications, figures, and standards, testing shall be performed on components listed in table VI for characteristics noted. Test reports shall be expressed as specified (see 6.2).

TABLE V. Component materials.

Component Characteristic Requirement paragraph

Inner headband Material identification 3.4.1 Headband outer cover and sweatband welt

Material identification 3.4.2

Sweatband Material identification 3.4.3 Sweatband seam reinforcement Material identification 3.4.3.1 Visor, top piece type I Material identification 3.4.4.1.1 Visor, bottom piece Material identification 3.4.4.1.2 Visor, top piece type II Material identification 3.4.4.2 Plumper paper or polyethylene interlining

Material identification 3.4.4.1.3

Adhesive Material identification 3.4.5 Binding Material identification 3.4.6 Rivets Material identification 3.4.10 Staples Material identification 3.4.11 Chin strap Material identification 3.4.14

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TABLE VI. Test methods.

Component Characteristic Requirement paragraph Test method

Number determinations per sample unit

Results reported as

Inner band Thickness 3.4.1 Micrometer 2 To nearest 0.001 inch Width 3.4.1.1 Gauge 1 Pass or fail Stiffness 3.4.1.1 4.4.1 1 Pass or fail Bending 3.4.1.2 4.4.2 1 Pass or fail

Binding Weight 3.4.6 Scale 2 To nearest ounce/yard Thickness 3.4.6 Gauge 2 To nearest 0.001 inch Finish 3.4.6 Visual 1 Pass or fail Color 3.4.6 Visual 1 Pass or fail

Staples Thickness 3.4.11 Gauge 2 To nearest 0.001 inch Grommet wire

Material identification

3.4.9 Standard

Commercial

X Pass or fail

Thickness of wire 3.4.9 Standard Commercial

X Average of 2 determinations per sample unit to nearest

0.001 inch

Thickness of pyroxylin

3.4.9 Standard

Commercial

X Average of 3 determinations per sample unit to nearest

0.001 inch

Spring steel Material identification

3.4.9 Standard

Commercial

- Pass or fail

Temper 3.4.9 Standard Commercial

- Pass or fail

Support stay and holder (50 pounds)

Type 430 stainless steel

3.4.7 ASTM E1282

2 Composite

X To nearest 0.01% of each element

Rivets Material identification and plating

3.4.10 Standard

Commercial

X Pass or fail

Bottom ply -polyethylene

Density 3.4.4.1.2 ASTM D792 X Grams/centimeters³ Melt index, I-2 3.4.4.1.2 ASTM D1238, 190/2.16 X Grams/10 minutes

Flexural modulus 3.4.4.1.2 ASTM D790, I/B

X Pounds/inch²

Tensile yield strength

3.4.4.1.2 ASTM D638 X Pounds/inch²

IZOD impact strength (notched)

3.4.4.1.2 ASTM D256 X Feet-pound-force/inch

Vicat softening point

3.4.4.1.2 ASTM D1525 X Degrees Fahrenheit

Hardness shore D 3.4.4.1.2 ASTM D2240 X Pass or fail

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4.3.1.1 Sampling for testing. Unless otherwise specified in subsidiary specifications, sampling shall be in accordance with table VII. The lot shall be unacceptable if one or more sample units fail to meet any test requirement specified herein.

TABLE VII. Material sampling.

Lot size (lot unit) Sample size (sample unit)

800 or less 2 801 through 22,000 3

22,001 and over 5

The unit for expressing lot size and sample unit for testing each component shall be in accordance with the applicable subsidiary specification and table VIII as follows:

TABLE VIII. Component sampling.

Component Lot size expressed as Sample unit for testing

Inner band feet 1 yard strip Sweatband seam reinforcement yard 1 foot length Binding 10 yards 1 square foot Rivets gross 3 each Staples gross 10 each Grommet 10 complete units 1 unit Clamp gross 10 each Crown support and holder 100 complete units 1 complete unit Button, button screw tube gross 10 complete units

4.3.2 Examination of end item. The defects found during examination of the end item shall be classified in accordance with 4.3.2.1. The sample unit shall be one cap frame.

4.3.2.1 Defects. Defects shall be classified in accordance with table IX.

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TABLE IX. Defects.

Examine Defect Classification

Major Minor

Material defects and workmanship 1/

Headband covering, sweatband welt:

Any hole or weakening defect, such as smash, multiple float, or loose slub that may develop into a hole.

Tears, mend, burn, cut, and needle chew. 102 Shade bar or unsightly slub:

On outside. 201 On inside. 202

Cleanness Any spot or stain clearly noticeable:

On outside. 103 On inside. 203 Five or more thread ends not trimmed, or loose thread ends not removed.

Components and assembly Any component or required operation omitted. 104 Any component not as specified. 105

Cutting Any component part not cut in accordance with specification requirements.

Seams and stitching Accuracy of seaming:

Seams twisted, puckered, or pleated, affecting appearance.

End of stitching (when not caught in other seam or stitching) backstitched less than 1/4 inch.

Stitching of thread breaks overlapping less than 1/2 inch at each end of break.

Any component part caught in an unrelated operation or stitching.

Wrong color thread. 208 Gauge of stitching:

Unevenly gauged, affecting appearance (to be scored only when the condition exists on major portion of seam):

On visor. 108 On all other components. 209

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TABLE IX. Defects – Continued.

Examine Defect Classification

Major Minor

Seams and stitching (continued)

Edge or raised stitching sewn too close to edge, resulting in damage to component.

Beyond range of width specified or varies more than 1/16 inch when no range is specified.

Open seams 2/:

Any seam open on visor joining seam, visor binding, sweatband joining to frame, back seam of sweatband, or back seam of cloth band.

Less than 1/4 inch. 211 More than 1/4 inch. 110 On all other seams:

Less than 1/4 inch. 212 1/4 inch up to 1/2 inch inclusive. 213 More than 1/2 inch. 111

Raw edges 3/:

Any raw edge on binding on upper edge of visor or on cloth at bottom edge of cap frame.

Run-offs:

On joining seam – when resulting in an open seam, use “Open seam” classification.

Edge or raised stitching (when not resulting in an open seam):

1/4 inch up to 1/2 inch inclusive. 215 More than 1/2 inch. 216

Seam and stitch types:

Not specified seam or stitch type. 113

Stitch tension:

Loose tension resulting in a loose seam or exposed loose top or bottom thread:

On visor joining seam or on stitching of visor binding.

On all other seams or stitching. 217 Tight tension (stitches break when normal strain is applied to the lengthwise direction of seam or stitching). 4/

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TABLE IX. Defects – Continued.

Examine Defect Classification

Major Minor

Seams and stitching (continued)

Stitches per inch (to be scored only when the condition exists on major portion of seam).

Less than minimum specified except on hand felling of sweatband:

1 stitch. 218 2 stitches. 219 3 or more stitches. 116

Less than minimum specified on hand felling sweatband:

1 stitch. 220 2 stitches. 221 3 or more stitches. 117

Marking Combined identification and size label missing, incorrect, or illegible.

Visor Not securely or evenly stitched with sweatband welt to inner headband.

Set from vertical front of cap at an angle of more than 35 degrees or less than 30 degrees.

Center of visor offset by more than:

3/8 inch. 119 1/4 to 3/8 inch. 224 1/8 to 1/4 inch. 225

Skiving omitted on inside edge. 226 Front edge uneven or not molded to proper shape. 120 Binding not securely caught to edge of visor. 121 Binding not firmly and smoothly joined to visor edge, affecting appearance.

Binding is peeling, cracked, tacky, spotted, discolored, or blistered.

Finished width of binding on top of visor under 3/16 inch or over 1/4 inch (but of uniform width).

Binding not of uniform width on top of visor, affecting appearance.

Width of visor at center less than 2-3/16 inches or more than 2-5/16 inches.

Distance between ends of attached visor at headband less than 10-3/4 inches or more than 11-1/4 inches.

Poorly laminated, affecting appearance. 127 Visor joining seam, more than 3/16 inch or less than 1/16 inch from lower skived edge.

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TABLE IX. Defects – Continued.

Examine Defect Classification

Major Minor

Embroidery (type II) Omitted. 128 Not specified type. 129 Core yarn not fully covered with metallic ribbon. 229 Loose stitches. 230

Chin straps and loops Length of each section under 10 inches or over 10-1/2 inches.

Width of each section under 9/16 inch or over 11/16 inch.

Edges of straps or points or loop not embossed. (type I, class 1 or type II, class 3). Embossing acceptable if visible at distance of 18-24 inches.

Edges not stained or poorly stained. 233 Loop not securely stitched to top strap or not stapled with two staples.

Bottom section of loop not securely stapled to bottom strap or not stapled with two staples.

Length of loops under 1-1/8 inch or over 1-3/8 inches. 234 Center of hole under 11/32 inch over 13/32 inch from end of strap.

Size of eyelet opening or punched hole under 5/32 inch or over 1/4 inch.

Holes off center of strap over 1/32 inch. 237 Opening of loop narrow, curling edge of strap. 133

Buttons and screw tubes Center of tube under 9/16 inch or over 11/16 inch from lower edge of headband.

Distance of screw tubes from center of crown support less than 5-5/8 inches or more than 5-7/8 inches.

Any button or screw tube omitted. 135 Tube(s) not securely locked. 239 Button or screw tubes defective, affecting function. 136

Headband, outer covering Welt omitted. 137 Back seam not spread open or partially lapped over. 240 Back seam offset from center back of frame by more than 1/4 inch.

Back seam not in vertical position by more than 1/8 inch.

Outer band badly puckered, pleated, or twisted, affecting appearance.

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TABLE IX. Defects – Continued.

Examine Defect Classification

Major Minor

Headband, outer covering (continued)

Raised, irregular welt. 244 Outer band irregular in width by 1/8 inch or over (to be scored only when condition exists on major portion of band).

Inner band Crushed, broken, warped or misshapen, affecting serviceability or appearance.

Overlapped ends insecurely fastened. 246 Overlap not positioned either to the right or left of the center back.

Width under 2-3/16 inches or over 2-5/16 inches. 248 Ends overlapped under 3/4 inch or over 1-1/4 inches. 249

Grommet (with clamp) Not fabricated of pyroxylin coated spring steel. 139 When wire depressed together into figure 8 position, and released, it does not spring back to its original circular shape.

Coating is not smooth and adherent. Coating contains beads, blisters, lumps, specks, pits, or foreign matter.

Coating is missing, scratched, scuffed, abraded, or otherwise damaged, in area of:

1/16 inch or more in width or 1 inch or more in length.

More than 1/32 inch, but less than 1/16 inch in width or more than 1/2 inch, but less than 1 inch in length.

1/32 inch or less in width or 1/2 inch or less in length.

Not clean. 252 Length 1/2 inch more or less than required for size of cap.

Clamp hinge not on inside of grommet wire. 144 Clamp not securely clinched to wire. 253 Clamp does not function properly. 254 Rough or sharp edges on wire or clamp. 255

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TABLE IX. Defects – Continued.

Examine Defect Classification

Major Minor

Support stay and holder:

Finish Dirty. Surface contains grease, mill soil, or other foreign matter.

Design Any operation not in accordance with specified requirements.

Construction and workmanship

Component missing, cracked, fractured, bent out of shape, distorted, malformed, deformed, or otherwise impaired.

Assembly Not connected or joined as specified or poorly accomplished.

Sharp edge, burr or sliver that may injure personnel or damage fabric.

Rivet missing, wrong type or size, or is not peened.

Rivet can be removed by hand.

Rivet head broken off. 148 Clinch of rivet incomplete, insufficient, or set improperly. Rivet is loose/can be rotated by hand or tool.

Flexing of crown wire causes rivet to loosen or wire to separate.

Rivet insufficiently peened but it cannot be removed by hand.

Setting of rivet is poorly accomplished, resulting in sharp, rough edges.

Rivets are not placed equidistant from edges of the stay ±1/32 inch.

Rivets are not 5/8±1/32 inch apart, center to center. 262 Stay and support holder will not mate, or a loose fit is affected.

Assembled height less than 4 inches or more than 4-1/4 inches.

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TABLE IX. Defects – Continued.

Examine Defect Classification

Major Minor

Sweatband Edges of back seam out of alignment with outer covering seam by 1/4 inch or more.

Strip on underside of back seam omitted or not securely stitched.

Strip not trimmed even with top edge of sweatband. 266 Poorly felled to outer band and welt. Stitching of sweatband on outerband and welt is very irregular in appearance.

Ends not abutted properly. 268 Felling stitches exposed on outside of frame. 269 Twisted or puckered, affecting wearing comfort. 152 More than 1/8 inch above bottom edge of frame. 270 Width outside of tolerances (see 3.4.3) 271

Labels Combination identification and size label:

Omitted, incorrect, or illegible. 153 Misplaced. 273 Not securely caught in stitching, or stitching through the printing.

NOTES:

1/ Material defects are to be classified as indicated only when the condition is one which weakens the fabric or when it is so conspicuously located as to be clearly noticeable. Material defects which are inconspicuous and do not weaken the fabric shall not be classified as defects.

2/ A seam shall be classified as open when one or more stitches joining a seam are broken or when two or more continuous skipped or run-off stitches occur.

3/ Raw edges not securely caught in the stitching shall be classified as an open seam.

4/ Puckering is evidence of tight tension. When puckering is evident, seam shall be tested by exerting pull in lengthwise direction of seam or stitching.

4.3.2.2 Finished measurements. Any head measurement not in accordance with measurements specified in table III shall be classified as a defect.

4.4 Tests. The inner band shall conform to the requirements specified in paragraph 3.4.1 when tested in accordance with the tests specified in 4.4.1 and 4.4.2.

4.4.1 Stiffness test. The inner band material shall be tested for stiffness at room temperature according to ASTM D2821 - Stiffness, using a span length of 1 inch, a moment weight of 1 inch-pound, and measuring the load at 20 degrees on the angular deflection scale. The specimen shall be 1 inch wide by 4 inches long and it shall be cut from the center part of the band. There shall be three determinations per sample unit.

4.4.2 Bending test. The bending test shall be conducted in accordance with ASTM D6075.

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5. PACKAGING

5.1 Packaging. For acquisition purposes, the packaging requirements shall be as specified in the contract or order (see 6.2). When packaging of materiel is to be performed by DoD or in-house contractor personnel, these personnel need to contact the responsible packaging activity to ascertain packaging requirements. Packaging requirements are maintained by the Inventory Control Point’s packaging activities within the Military Service or Defense Agency, or within the military service’s system commands. Packaging data retrieval is available from the managing Military Department’s or Defense Agency’s automated packaging files, CD-ROM products, or by contacting the responsible packaging activity.

6. NOTES

(This section contains information of a general or explanatory nature that may be helpful, but is not mandatory.)

6.1 Intended use. The cap frame covered by this specification is for use with the service and dress cap crowns specified in MIL-DTL-18186 and is for the use of personnel of the United States Marine Corps.

6.2 Acquisition requirements. Acquisition documents should specify the following:

a. Title, number, and date of this specification.

b. Type, class, and size required (see 1.2).

c. When first article is required and the number of units for the first article (see 3.1 and 6.3).

d. Patterns (see 3.5).

e. Sampling for inspection (see 4.3).

f. Requirements for test reports (see 4.3.1).

g. Packaging requirements (see 5.1).

h. Acceptable quality limits.

6.3 First article. The first article sample should be a preproduction sample. The contracting officer should specify the appropriate type of first article sample and the number of units to be furnished. The contracting officer should also include specific instructions in acquisition documents regarding arrangements for selection, inspection, and approval of the first article sample.

6.4 Subject term (key word) listing.

Embroidery Enlisted Officer Poromeric

6.5 Changes from previous issue. Marginal notations are not used in this revision to identify changes with respect to the previous issue due to the extent of the changes.

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FIGURE 1. Requirements for visors.

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For information only. All measurements in inches.

FIGURE 2. Requirements for support stay and holder.

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For information only. All measurements are in inches.

FIGURE 3. Requirements for grommet and crown support.

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FIGURE 4. Exploded view – requirements for clamp and assembly.

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FIGURE 5. Requirements for chin straps.

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FIGURE 6. Requirements for frame – side view.

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FIGURE 7.