Hat Making Accessories: Tools and Materials for Customizing Hats
Hats aren't just functional headwear. They're a way to express yourself, a piece of wearable fashion art and a nod to cultural heritage. The right hat-making accessories are a must for anyone crafting one-of-a-kind pieces, whether you're sewing couture hats, messing around with DIY projects or running a print-on-demand shop that sells custom hats online.
The booming global hats market only underscores what a great opportunity this is. Fortune Business Insights reports the market is set to grow from USD 11.04 billion in 2025 to USD 16.61 billion by 2032, with a compound annual growth rate of 6.01%.
This guide breaks down all the key accessories you'll need for hat making. We cover everything from foundational tools and materials to decorative embellishments and maintenance solutions. Master these basics, and you'll level up your designs, work more efficiently and create hats that are as beautiful as they are practical.
Essential Tools and Materials
Millinery Tools for Hat Making
Any great hat starts with the right tools. Millinery is the craft of making hats, and it relies on specialized gear to shape, cut, join and refine designs. These tools are just as crucial for print-on-demand sellers, who need to make sure their base hats can handle custom prints or embroidery.
Hat Blocks and Forms
A hat block is a shaped form, typically wood or metal, used to mold a hat's crown and brim into your desired style. Different blocks create distinct looks, so many milliners collect a variety of shapes to keep their creative options open.
For print on demand hats, blocks are useful for prototype samples. Using a correctly shaped block ensures that the base hat maintains the right structure so digital designs, embroidery, or heat transfers will align properly.
Blocking Pins and Awls
Blocking pins and awls hold materials firmly in place on the block while you shape the hat. If you're a print-on-demand seller tinkering with custom designs, these tools come in handy for making small batches or prototypes. They let you check exactly how prints and embellishments will look on the finished product.
Cutting and Sewing Tools
High-quality scissors and needles are indispensable, especially for materials like felt, straw, or cotton caps. For print on demand products that include custom stitching, embroidery, or sewn trims, the right tools help ensure clean lines and professional results.
Measuring and Fitting Tools
Accurate measurements are critical for fit and comfort. Tape measures, size gauges, and hat stretchers help ensure that hats meet standard sizing or custom orders. For print on demand operations, properly sized hats reduce returns and improve customer satisfaction.
Specialty Tools for Advanced Hat Making
For those who want to push design boundaries or create more complex structures, advanced accessories and tools offer expanded creative potential.
Millinery Wire and Shape Reinforcements
Wire reinforces brims or creates decorative frames. For print on demand hats with complex structures, wire ensures that digital or physical embellishments maintain their intended form.
Steamers and Pressing Cloths
Steam softens hat materials for shaping. Pressing cloths prevent damage during ironing, particularly for hats printed or embroidered with print on demand designs.
Specialty Adhesives and Glues
Adhesives are used for securing trims or structural components. For print on demand hats with applied trims or branding elements, non-toxic, durable glues ensure the final product withstands shipping and everyday wear.
Hat Materials and Foundation Components
Materials form the body and structure of a hat. Choosing suitable materials is particularly important for print on demand, as not all fabrics or trims are compatible with digital printing or heat transfer processes.
Millinery Fabrics and Interfacing
Common hat bases include wool felt, straw, sinamay (a type of woven straw), and buckram. Felt offers excellent structure and surface for decoration, while straw and sinamay work well for lighter, breathable summer hats. Buckram is a strong, stiff fabric often used to build foundations like the crown or brim before covering it with more refined outer materials.
Sweatbands and Liners
Interior comfort and fit are enhanced by sweatbands and liners. These accessories are usually made from softer materials such as grosgrain, leather, or cotton. For print on demand hats, liners also prevent moisture from affecting printed designs and protect the hat during handling and shipping.
Brims, Crowns, and Protective Inserts
Structural components like brims and crowns define a hat's silhouette. Plastic or cardboard inserts can reinforce shapes, especially for wider brims. For print on demand production, these inserts ensure that digital designs and embellishments maintain proper alignment and structure throughout fulfillment.
Decorative Accessories for Custom Hats
Once a solid foundation is in place, decorative accessories bring hats to life. From classic ribbons to whimsical feathers, these elements allow for personalization and creativity.
Hat Bands
Hat bands are strips of fabric, leather, or ribbon wrapped around the crown of a hat. They are a timeless way to add contrast, thematic color, or seasonal flair to a piece. Leather bands evoke rustic and western styles, while satin ribbons can add elegance to dress hats.
Feathers, Flowers, and Embellishments
Decorative elements like feathers, flowers, and artificial blooms add sculptural interest and personality. These trims are especially popular in fashion hats or bespoke designs where attention to detail and artistic expression are key.
Pins, Clips, and Badges
Functional but ornamental, pins, clips, and badges allow creators to attach trims securely while also giving wearers the option to interchange pieces. Metal badges, enamel pins, or decorative clips can reinforce theme or branding.
Trim Materials
Textile trims such as grosgrain, lace, and braided bands provide texture and depth. These materials frame the hat's shape and help blend decorative elements with the base material.
Functional Accessories and Maintenance Tools
Accessories aren't all about looks, as many are designed to help maintain the hat's quality and longevity.
Hat Brushes and Cleaning Equipment
Regular brushing removes dust and restores nap on felt or straw hats. For print on demand sellers, instructing customers on care helps maintain product appearance and prolong lifespan.
Weather-Proofing Sprays and Covers
Protective sprays can repel water and prevent sun damage to materials like felt and straw. Storage covers or cloth bags shield hats from dust when they aren't being worn.
Hat Boxes and Storage Solutions
A quality hat box preserves shape and protects hats during storage or travel. These containers come in various sizes and can include padded interiors or handles for easy transport.
Choosing the Right Accessories Based on Hat Style
Different hat styles benefit from specific accessories. Understanding these distinctions helps tailor your designs to purpose and audience.
Straw Hat Accessories (Summer & Beach Hats)
Lightweight trims, breathable bands, and printed decorations are ideal for summer hats. print on demand sellers can use printed patterns to simulate natural textures.
Felt and Wool Hat Accessories (Winter Hats)
Seasonal accessories for felt or wool hats include weather-proofing sprays and warm liners, making them comfortable and durable in cold conditions.
Casual and Streetwear Hat Accessories
Leather bands, metal hardware, and minimalist trims work well with casual or streetwear hats. Customization allows logos or graphic prints on caps for fashion-forward customers.
Formal and Fashion Hat Embellishments
Decorative elements such as silk ribbons, veiling, and couture-level flower trims elevate a hat to formal wear status.
Conclusion
Crafting hats by hand or designing custom products for a print-on-demand business requires the right accessories. These tools are key to achieving quality, style, and happy customers.
By understanding the role of each accessory and how it interacts with print on demand production, sellers can offer hats that are not only fashionable but also durable, comfortable, and personalized.
Written by Suey
Suey is a fashion-focused SEO writer with expertise in print-on-demand. She creates practical, trend-driven content covering custom apparel, design inspiration, and print on demand best practices, helping sellers and brands navigate the competitive eCommerce landscape.
