Craftsmanship
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.
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.
STEP 7 TO 30
SEWING IT TOGETHER
The hand cut materials, 15 separate pieces sewn together by talented artisans. From topstitching the brim, making the crown (seven steps alone!), to attaching the sweatband and inserting the brim wire; each step is meticulously followed – with 23 different sets of hands involved.
STEP 31 TO 41
FINISHING TOUCHES
The finishing touches are added: wind cords & crown foam. Only once every loose thread has been snipped and the hats steamed are they ready to leave the factory.
