1. Consultation & Design

Getting started is easy. Most clients begin by filling out our detailed Custom Hat Order Form, where you’ll choose your preferred quality, color, crown, and brim shape. If you’d like personalized guidance, our expert stylists are always available for a one-on-one consultation to help bring your vision to life.

2. Precision Measuring with Augmented Reality

We use advanced augmented reality technology to capture your exact head measurements—from anywhere in the world. This innovative process ensures a perfect fit, no matter where you’re located. Prefer the classic way? We’ll send you a head measuring kit if you’d rather do it by hand.

3. Selecting Premium Materials

Your hat begins with the finest materials: 100% pure beaver, mink, or a blend felt. Choose from a variety of rich colors and finishes, each selected for its durability, feel, and timeless look.

4. Handcrafted Blocking & Shaping

Once your materials are selected, our master hatters steam and block the felt by hand, forming the base shape of your crown and brim. This is where your hat begins to take its iconic form.

5. Custom Crown & Brim Shaping

Your chosen crown and brim are expertly hand-shaped to your specifications. Whether you prefer a cattleman crease, a punchy look, or something entirely your own, we bring your vision to life with precision and care.

6. Goat Skin Sweatband: Comfort & Fit Redefined

Every JW Brooks hat features a hand-sewn sweatband crafted from fine, supple goat skin. The band is carefully drawn through the temple to the front of the hat, ensuring your hat stays secure—even in the wind. It’s a fit that feels like air but wears like armor.

7. Fine Finishing Touches

From sanding and smoothing the felt to sewing in your custom liner, every detail is finished by hand. We offer custom hatbands, stitching, initials, and other personalized accents to make your hat one-of-a-kind.

8. Quality Inspection & Final Approval

Before leaving our hands, your custom hat goes through a rigorous quality check. We inspect every stitch, crease, and finish to ensure it meets the high standards that JW Brooks is known for.

9. Delivery to Your Doorstep

Once complete, your custom hat is carefully packaged and shipped worldwide—ready to wear, wherever you roam.

Ready to start your custom hat?