Our Craft

Every Hills Hat begins with the right materials. We source premium felts, fabrics, ribbons, leather and trims from specialist suppliers around the world, choosing each for its quality, character and performance.

Once the materials arrive in our workshop, they are carefully measured, cut and prepared for construction. Depending on the style, components may be fused or reinforced to give the finished hat the right structure, shape and durability.

Our skilled machinists bring the individual pieces together, carefully sewing the crown, brim and other components to create the foundations of the hat. Every seam and stitch contributes to the strength, fit and finished character of the design.

Using traditional hatmaking techniques, we shape each style according to its intended silhouette. Steam, specialist blocks, moulds and shaping techniques are used across our range — from structured felt hats to flat caps, bucket hats and other headwear.

The final details bring the hat to life. Ribbons, leather trims, bands, badges and other finishing touches are carefully applied, before each hat is inspected, shaped and prepared for its new owner.