A method for fabricating a custom headwear for a subject is described. The method comprises generating a three-dimensional head data file for the subject and determining contour lines on the head; automatically generating a headwear data file. The method further comprises juxtaposing the headwear represented by the headwear data file with the head represented by the three-dimensional head data file having the contour lines thereon. The method yet further comprises utilizing the headwear data file to generate a shape for a desired headwear, the shape having an interior surface to contact the head and an outer surface. Still further, the method comprises projecting lines outward from the contour lines to the outer surface; and utilizing the projected lines to establish headwear contour lines for the custom headwear.