Custom hat making

Each Sadie James hat is made with the intention of originality in mind. Our custom design process has been curated over the years to be a unique experience for anyone that is looking for a hat that stands apart from the crowd. No matter if you're designing an heirloom to pass down for generations to come, want something that makes your outfit pop for a special event, or just need an every day staple to tie your look together, our hats are made for all of life’s wild rides

A person shaping a piece of leather with a tool, likely a leatherworking process, with focus on their hands and the leather.
A person is ironing a black hat with a steam iron.
Close-up of two beige felts hats resting on a wooden surface with a black hat hanging on a white brick wall in the background.

Stretching

The journey begins with stretching—the moment raw felt transforms into possibility. Using steam and skilled hands, we stretch the felt over a wooden hat block, coaxing it into the early silhouette of what’s to come. It’s the foundation of form, where precision meets patience.

Person wearing a cowboy hat with feathers and a silver chain, bent over a black object on a wooden surface, in front of a white brick wall with hats on shelves.
Black silhouette of a witch riding a broomstick with a cauldron and witch hat, surrounded by stars and a crescent moon.

Pouncing

pouncing is a traditional technique used to smooth, refine, and finish the surface of a felt hat body. It involves gently sanding the felt with an abrasive material—typically sandpaper or pumice—either by hand or with a pouncing machine.

Woman wearing a cowboy hat with a chain, pressing a black hat with a hammer on a wooden surface. Hats are hanging on a white brick wall in the background.
A black cat sitting on a windowsill at night, looking out the window.

Firing

A small black hat on a wooden plate, with flames and blue smoke burning on top, in front of a dark brick wall.

In firing, we lock the shape into place. Through steam, heat, and pressure, the hat’s structure is solidified, setting the crown and brim with intent. This is where durability is forged, and the hat gains the strength to stand the test of time.

Black silhouette of a spider with long legs on a black background.

Shaping

A woman wearing a cowboy hat and black outfit, looking down as she touches a large object, with a white brick wall and ceiling in the background.

Shaping is where the soul of the hat emerges. Whether it’s a sharp teardrop crown, a wide cowboy brim, or a custom curve, this step is fully tailored to the wearer’s vision. It’s sculptural, hands-on, and deeply personal—no two shapes are ever truly alike.

Black and white illustration of a wolf howling at the moon.

Designing

A person with curly blonde hair working on a piece of leather at a wooden workbench, with a worn hat nearby.

Finally, we bring it all together with designing. This is the artistry: selecting the right trim, adding stitching details, burnishing the brim, or branding the leather sweatband. Every element is chosen with intention, turning craftsmanship into character.

Black silhouette of a woman lifting weights at gym.
A woman with long wavy hair wearing a cowboy hat, looking at a distressed hat with a chain decoration, in front of her. She is sitting indoors against a white brick wall.
Design a Custom Hat