Craftsmanship

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We’re often asked, what does it take to make a Tilley hat? In all, there are 46 hands that follow 41 steps, a precise and practised process that begins with cutting cotton and foam canvas and ends with steaming and packing the handcrafted final product. In between, we’re busy joining, binding, lining, stitching and adding those essential signature details that distinguish a Tilley hat from all others.

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SIZING

Like footwear, ultimate performance and comfort is best delivered with a properly sized product. We take great pride in offering a bespoke sizing experience for the majority of our outdoor performance hats.

STEP 1 TO 6

PREPPING & CUTTING

It all starts with the fabric. After unravelling and spreading out yards of fabric, the cutting begins. Brim, binding and the crown are cut in small batches to ensure consistency. For the mesh style hats, the mesh is attached to the crown.

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Prepping & Cutting

STEP 7 TO 30

SEWING IT TOGETHER


It all starts with the fabric. After unravelling and spreading out yards of fabric, the cutting begins. Brim, binding and the crown are cut in small batches to ensure consistency. For the mesh style hats, the mesh is attached to the crown.

Prepping & Cutting

STEP 31 TO 41

FINISHING TOUCHES


The finishing touches are added: windcords crown foam, owner’s manual. Only once every loose thread has been snipped and the Hats steamed are they ready to leave the factory.

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