A system for making a fitted cap , the fitted cap configured to apply a shaped sealant shroud to a portion of a fastener , the system comprising: a support plate , comprising: a first side ; a second side , opposite the first side ; and a first plurality of through-openings , penetrating the support plate from the first side through to the second side ; a fastener template , dimensionally identical to the portion of the fastener and extending from the first side of the support plate such that the first plurality of through-openings is arranged about the fastener template ; a precursor cap , comprising a first surface , geometrically complementary to the fastener template , and a second surface , opposite the first surface and parallel to the first surface ; first means for heating a first polymer sheet to a specified temperature; and second means for applying suction to the first polymer sheet , positioned a predetermined distance from the first side of the support plate and heated to the specified temperature by the first means , through the first plurality of through-openings from the second side of the support plate to vacuum-form the first polymer sheet over the precursor cap , wherein the second means is configured to apply the suction such that: after vacuum-forming the first polymer sheet over the precursor cap , at least a portion of the first polymer sheet forms the fitted cap and a first inner surface of the fitted cap is geometrically complementary to the second surface of the precursor cap . a support plate , comprising: a first side ; a second side , opposite the first side ; and a first plurality of through-openings , penetrating the support plate from the first side through to the second side ; a first side ; a second side , opposite the first side ; and a first plurality of through-openings , penetrating the support plate from the first side through to the second side ; a fastener template , dimensionally identical to the portion of the fastener and extending from the first side of the support plate such that the first plurality of through-openings is arranged about the fastener template ; a precursor cap , comprising a first surface , geometrically complementary to the fastener template , and a second surface , opposite the first surface and parallel to the first surface ; first means for heating a first polymer sheet to a specified temperature; and second means for applying suction to the first polymer sheet , positioned a predetermined distance from the first side of the support plate and heated to the specified temperature by the first means , through the first plurality of through-openings from the second side of the support plate to vacuum-form the first polymer sheet over the precursor cap , wherein the second means is configured to apply the suction such that: after vacuum-forming the first polymer sheet over the precursor cap , at least a portion of the first polymer sheet forms the fitted cap and a first inner surface of the fitted cap is geometrically complementary to the second surface of the precursor cap . after vacuum-forming the first polymer sheet over the precursor cap , at least a portion of the first polymer sheet forms the fitted cap and a first inner surface of the fitted cap is geometrically complementary to the second surface of the precursor cap . <EOS>