The process of hat making is a remarkable blend of craftsmanship, creativity, and tradition. At SoonNoon, we take pride in our commitment to handmade products, where each hat is a testament to the dedication and skill of our artisans. Here’s an easy-to-understand overview of the steps involved in crafting our unique hats.

1. Selecting Quality Materials: Every hat begins with choosing high-quality materials, such as premium felt or 100% Toquilla straw. These materials are essential for creating hats that are not only stylish but also durable and long-lasting.

2. Preparing the Felt: For felt hats, we start with a single piece of premium felt, which is steamed to open the fibers, making it pliable for shaping. This initial step is crucial for achieving the perfect fit.

3. Shaping the Hat: The softened felt is then placed over a specially crafted wooden block, designed for each style. It is secured with a block string to maintain the desired shape, creating a defined break between the crown and the brim.

4. Molding the Brim: Using a heated iron, we carefully mold the brim of the hat. This heat allows us to flatten and shape the felt, ensuring a polished finish. After shaping, the hat is left to dry, allowing the felt to set firmly into its new form.

5. Pouncing the Felt: An important step in the hat-making process is pouncing, where the felt is sanded down to achieve a smooth surface. This sanding not only enhances the texture of the hat but also prepares it for the final shaping and embellishments.

6. Using Fire for Finishing Touches: In some cases, we use fire to trim the surface of the felt. This technique helps seal the fibers and prevents fraying, ensuring a clean and professional look. It’s a delicate process that requires skill and precision, underscoring the importance of craftsmanship.

7. Adding the Sweatband: Once the felt has been shaped and prepared, we hand-sew a leather sweatband into the hat. This sweatband enhances comfort and durability, making the hat suitable for everyday wear. Each band is cut to size and stitched in place, featuring a ribbon to mark the back of the hat.

8. Hand-Shaping: The next phase involves hand-shaping the crown and brim to achieve the desired style. This requires careful attention and fine-tuning, ensuring that each hat meets our high standards of quality, look and feel.

9. Embellishing the Design: With the hat shape in place, we focus on decorative elements such as ribbons, cords, and edge binding. These details reflect our commitment to individuality and artistry, allowing each hat to showcase its unique character.

10. Signature Time Stitches: To complete the hat, we add our signature time stitches, marking it as a SoonNoon creation. These stitches represent the passion and craftsmanship behind every piece we produce.