The Unique "Made in USA" Items from "KAVU" that Brighten Outdoor Scenes

Most people have probably seen a cap with outdoor webbing tape circling around the head at least once. This item is known as the "Strapcap," which represents the Seattle-born brand, "KAVU."

After launching in 1993, the brand entered the Japanese market almost without delay and now has a wide fanbase. In this article, we’ll talk to Kiyonobu Nannichi from A&F Corporation, introducing Made in USA items that stand out among KAVU's extensive line-up and exploring the brand’s history as well.

The Challenging Seas of Alaska Inspired the Iconic Strapcap

"Let me start with the history of the brand. The founder is a man named Barry Barr, who, encouraged by his father, bought a fishing boat in his youth, obtained a fishing license, and started running Bristol Bay Boat, a salmon fishing company in Alaska.

"Fishing on Alaskan seas meant enduring intense winds and strong sunlight reflecting off the water. Amid these harsh conditions, he thought, 'What if I made a sun visor that wouldn’t blow off in the wind, but would also shield against the sun?' That idea eventually led to today's signature Strapcap.

"In 1993, KAVU was established in Seattle, and the 'Strapcap' was released.

"The Strapcap, a completely new concept at the time, was first introduced to the ski market in its launch year, then rapidly gained traction in the outdoor, canoe, and kayak scenes the following year. At the 1996 Atlanta Olympics, it was even chosen as the official licensed product of the US Canoe & Kayak Team, quickly raising KAVU’s standing as an outdoor brand.

"The brand name KAVU draws inspiration from the aviation term CAVU (Clear Above Visibility Unlimited), meaning 'perfectly clear visibility'; the C was swapped for a K to create KAVU.”

"I Want to Make the Toughest Cap in the World"—A Deep Dive into the Strapcap

Let’s take a closer look at the Strapcap, the item that kicked everything off. We'll explore the background, and specifics of the design as the story continues.

"Through his work on Alaskan waters, Barry developed the ambition to 'make the toughest cap in the world.' He began by attaching outdoor webbing tape to the brim of a regular cap, prototyped a version with improved adjustability, and searched tirelessly for a sewing factory capable of mass production.

"Seattle in the 1990s had a thriving outdoor culture, with several sewing factories specializing in products like backpacks. Among them, Barry connected with a factory that resonated with his vision, and together they brought the Strapcap to life.

"And so, with only this cap, the KAVU brand began. Even now, as the brand has grown, KAVU continues its close relationship with the original manufacturer.

"Shortly after KAVU’s launch, at an Outdoor Retailer Show in Reno, Nevada, our company’s chairman met Barry, which sparked KAVU’s Japanese debut. At that time, the outdoor wear boom in Japan was in full swing, and the Strapcap quickly became popular, loved by many to this day."

“Let’s talk about the product specifics. The biggest feature is the size-adjustable webbing tape sewn along the brim. Thanks to this webbing system, the cap won’t easily fly off even in strong wind.

"This webbing tape comes in a wide variety of colors and patterns, and since the selection is generally left up to chance, collecting different combinations is part of the fun and popularity. The body is made from tough canvas that ages beautifully over time, developing unique character with use—a big reason people keep loving this product.

"Additionally, the underside of the brim is unified in black to prevent harsh sunlight from reflecting off surfaces like water. Nowadays, KAVU is also making efforts toward sustainability, manufacturing apparel from 100% organic cotton."

Not Just the Strapcap—KAVU's Proud "Made in USA" Items

Now, let's take a look at some Made in USA items that showcase KAVU's unique style, following the iconic Strapcap.

"I'd like to introduce two items released in the 1990s, soon after the birth of the Strapcap. 'Chilliwack Shorts' and 'Half Zip Throwshirt' are both Made in USA pieces that truly embody what KAVU is all about.

The Chilliwack Shorts are crafted from tough 10oz organic cotton canvas. They feature the distinctive 'Half Moon Pockets' on the front and back, designed to be handy for climbing. With a relaxed silhouette, they're versatile enough for city wear and the outdoors alike, and can even be layered for use beyond summer. They're a must-have item for anyone's wardrobe."

"Next, the 'Half Zip Throwshirt' is also made using thick organic cotton fabric, making it a perfect outer layer for camping trips or cooler seasons.

"Key details include a half-zip front and hook-and-loop fasteners at the cuffs, completely forgoing buttons in the design. This is an idea that comes straight from Barry's time working on boats—buttons could get caught on fishing nets, so this was his clever workaround.

"Of course, the Half Zip Throwshirt itself isn't specifically for fishing, but Barry's hands-on experience is reflected in the design, which is part of what makes this item so distinctively KAVU. Like the Strapcap, it also features a 'webbing tape pocket' on the chest, serving as an eye-catching accent.

"What further established the appeal of these two items were the easy-care feature, making them simple to wash, and the use of natural fibers, which are less likely to burn holes from campfire sparks compared to synthetics. User feedback over the years has helped raise awareness of their value and convenience, cementing them as KAVU's signature products."

A True KAVU Original—The Umbrella-Like "Chillba"

There's another Made in USA item that could only be from KAVU. Let's talk about the 'Chillba,' inspired by Japan's Kasa-boshi (umbrella hat) and Vietnam's Non La.

"After returning from a trip to Asia, Barry was determined to turn this 'umbrella hat' concept into a product. He approached his usual sewing factory and, to get his idea across, actually cut a pizza box into a circle! At the time, the factory had urethane material for making backpacks, and they used it to craft the first Chillba prototype.

"This is how the uniquely KAVU sunhat, 'Chillba,' was born. It doesn't just shield your whole body from the sun; it's also designed to float on water, making it perfect for river play, stand-up paddleboarding (SUP), and all kinds of waterside activities. On hot, sunny days, it's truly a must-have item.

"Thanks to the adjustable chin strap, you can secure it firmly even on windy days. Plus, its soft foam material lets you fold it up for easy carrying—making it an incredibly practical choice."

Since the 1990s, KAVU has been a beloved outdoor brand in Japan.

The brand has grown each year, with items now produced in various countries. However, there are still products that remain proudly Made in USA. These enduring, innovative creations are a testament to KAVU's unwavering philosophy.

If you don't yet own a KAVU piece, why not start with the Strapcap—the cap born from the dream of making "the toughest cap in the world"?