How a Smithbilt hat is made
Smithbilt hats are made from felt or wool. We source our wool hats from selected, small manufacturers around the world. We fashion Smithbilt felt hats in our Calgary factory, using time-honored processes and tools.
- Selecting the felt
For every hat, there is the perfect felt. Our felts are made by craftspeople across North and South America. Each produces material of a unique texture and quality. They manufacture hat bodies to our specifications of color, weight and composition.
- Blocking
When we have the right felt, we select one of our hundreds of classic hardwood hat blocks – the forms that define the size and crown shape of the finished hat. We place the felt body over the block, then steam and press it in a blocking machine.
- Die and saddle
To create the hat’s unique Smithbilt style, we further press the blocked body in a hydraulic machine using a die and a saddle.
- Crafting the brim
The blocking process leaves marks on the outer edge of the brim, so the edges are trimmed with a brim cutter. We steam the brim, place it in a flange plate and heat it using a plating machine. For some hats, we shape the curve of the brim by hand. Brim shaping is a fine art, and takes a well-trained eye.
- Detailing
Once the hat is fully formed we hand-stitch the sweatband, lining and band, creating the distinctive Smithbilt finishing touches.
- Cleaning and inspection
Finally, the Smithbilt hat is carefully cleaned and inspected. If it’s not perfect, it’s back to Step One.
- Packing
before it is shipped
The Smithbilt hat is doubly protected, first in a protective bag and then in a specially constructed hatbox.
What Makes a Good Hat
Hats are most commonly made from Straw, Wool Felt, Fur Felt or Beaver Felt.
Prices are based on the quality of the felt with wool felt hats and lower grade straws being the least expensive.
Felt hats are produced from Beaver or Rabbit Fur. These two furs are blended in different percentages of each to produce different qualities or X’s. The beaver fur has characteristics that produce a high quality felt that will stand the test of time. The compositions of fur combined with the level of workmanship in the hat determine the X quality of each hat.
The higher the X, the more expensive the hat tends to be. This is due to higher concentrations of beaver fur and workmanship in the hat. A 100X hat, for example, is made of 100% Beaver fur and requires up to 5 hours of hand sanding and shaping before it is worthy of the 100X Smithbilt brand.
Whatever your requirements, Smithbilt has the products to meet any budget.
