For the Fall 2011 Headwear Product Offering I manipulated some style guide art from Marvel, DC, and Hasbro that basically removed one color from each character. That color would then be represented by the fabric color the character would be High Density screenprinted on. Ultimately we ended up having the art on the 3/4 view of the cap, requiring the factories to line up the image over the seam. When it lined up, it looked great!
These posters are just me having fun with the art afterwards.
Hasbro Selling Tools details for Materialize cap
Marvel Selling Tools details for Materialize cap
Warner Bros. DC Comics Selling Tools details for Materialize cap