How Handmade Hats Are Made: Inside the OTRHATS Studio Process

July 21, 2025

From raw materials to a timeless crown, step into the artistry of handcrafted hats.

🧵 The Art Behind Every Crown

At OTRHATS, we don’t just make hats—we shape identity, one crown at a time. Each hat begins as a vision and becomes reality through the hands of skilled artisans in our studio.

Whether it’s a summer straw fedora or a wool felt pork pie, every OTRHAT tells a story. And like all great stories, it starts with intention, patience, and craftsmanship

🔍 Step 1: Sourcing the Finest Materials

We begin with premium materials, carefully selected for durability, comfort, and style.

Straw Hats: We use 100% Shantung and raffia straw—lightweight, breathable, and structured.
Wool & Felt Hats: We source ethically processed wool felt with a luxurious finish, made to last for years.

Textural detail of natural straw hat handcrafted by OTRHATS – showcasing weave and quality

✂️ Step 2: Blocking the Crown – Shaping the Identity

Each hat starts with a “blank,” which is carefully steamed and hand-shaped using traditional hat blocks. We mold the crown—whether a classic Cattleman, teardrop, or pork pie—according to the design.

This shaping process requires precision and experience. No two blocks are exactly the same, and no two hats are ever truly identical.

💬 Fun fact: Our favorite wooden blocks are over 20 years old and still in use today.

Step 3: Hand-Stitched Brims & Finishing Touches

Once the crown is set, it’s time to finish the brim. Each brim is cut, steamed, and edged by hand. Some styles feature a bound-edge ribbon for structure, while others embrace a raw, natural finish.

We then hand-sew the sweatband and lining, ensuring comfort and breathability. Every hatband, feather, or accessory is individually selected and placed with intention.

Artisan-crafted hat featuring meticulous hand stitching and detailed handmade construction, showcasing expert craftsmanship and timeless design.

🎨 Step 4: The Signature OTRA Details

What sets OTRHATS apart isn’t just craftsmanship—it’s character.

From vintage-style ribbon wraps to symbolic feathers, every detail is part of a narrative. Some hats include custom branding stamps or limited-edition design elements, crafted for collectors and creatives alike.

Custom handcrafted item featuring unique hand-painted details, highlighting personalized artistry and meticulous craftsmanship.

🏷️ Final Step: Quality Check & Branding

Before a hat leaves our studio, it undergoes a meticulous final check:

Is the stitching clean and secure?
Is the shape true and balanced?
Does it meet the OTRHATS standard?

Only then is the gold label added—the seal of a hat made not just by hand, but by heart.

🌵 Why Handmade Still Matters

In a world of fast fashion, OTRHATS stands for something slower, something truer. We believe handmade hats preserve tradition, elevate quality, and offer something far more personal than mass-produced alternatives.

When you wear an OTRHAT, you’re not just wearing a hat—you’re wearing hours of care, decades of tradition, and a piece of someone’s craft.