A process of fabricating a headgear device is disclosed comprising a crown section (524) and a strap section (526). Both sections include a skin-facing fabric layer (512, 502), an outer fabric layer (520, 508) and a foam layer (504, 506, 514, 518) between the fabric layers. The strap section further includes a layer of rigid material (516) located between the skin-facing fabric layer (512) and the outer fabric layer (520).
