A manufacturing method including providing a mold including at least two mold parts having first and second molding surfaces which are complementarily profiled to give shape to headwear; shaping a first substrate in the mold resulting in the first substrate having a non-planar profile which matches at least a portion of the profile of the molding surfaces; shaping a second substrate in the mold resulting in the second substrate having a non-planar profile which matches the profile of the molding surfaces; overlaying the first substrate on the second substrate and matching their non-planar profile to form a combined substrate; placing a third substrate in the mold with the combined substrate, sandwiching the first substrate; and shaping the third substrate with the combined substrate in the mold resulting in the third substrate having a non-planar profile which matches the profile of the molding surfaces, thereby forming a seamless structure for the headwear.