Hat manufacturing capabilities
A hat’s character comes from its shape, its materials and the details that bring it together.
Bring your ideas to Dorfman Milano. Our in-house designers and manufacturing team work with you to develop the construction, trims and finishing touches that make a hat your own—from Western and dress styles to outdoor headwear, caps and knits.
Hat styles to make your own
A Western crown. A dress silhouette. A cap with your brand’s point of view. Start with the kind of hat you want to create, then explore the materials and details that will give it character.
Western & cowboy hats
Resort & sun hats
Outdoor & performance hats
Fedora & dress hats
Bucket hats & visors
Baseball, trucker & other caps
Beanies & knit headwear
Kids hats
For our Garland and global manufacturing story, explore Custom Hat Manufacturing.
Develop Your Hat with Our Designers
Original Concepts and Existing Designs
Bring a sketch, an inspiration or a design you’ve already developed. Our in-house designers can work with you on an original hat, or help develop changes to the material, color, trim and styling of an existing design.
If you want to put your logo, labels and packaging on an existing Dorfman style, explore Private Label Hats.
Technical Specifications and Patterns
Behind the finished hat are the specifications and patterns that define its design. We develop these with you as part of your manufacturing project, or work from the specifications your team has already prepared.
Whether your starting point is a sketch or a developed tech pack, we can help take the design into manufacturing. For brands with an established design, we also offer contract manufacturing to customer-supplied specifications.
Shape, materials & finishing details
Materials and shape
The line of a brim, the shape of a crown and the texture of the material all contribute to a hat’s character. Our designers work with you on these choices, whether you’re developing a Western silhouette, a dress hat or casual headwear.
Bring the look and feel you have in mind. We’ll explore the material and shape together, with the construction and finishing details of the hat in view.
Cut-and-sew construction
The pattern gives a sewn hat its shape. Construction brings the pieces together. We offer pattern development and cut-and-sew production, working from your specifications or developing them with you as part of a manufacturing project.
Trims, linings & branding
The trim around the crown. The lining inside. The label carrying your name. These details are part of the hat’s design.
Explore trims, embellishments, labels, hangtags, sweat prints and linings suited to your style. We’ll consider them alongside the materials and construction, so your branding becomes part of the finished hat.
For our Garland and global manufacturing story, explore Custom Hat Manufacturing.
Hat manufacturing questions
Can you manufacture hats from our designs or specifications?
Yes. We manufacture to customer-supplied designs and specifications, and we can also provide design support when your project begins with a sketch or concept. Technical specifications and pattern development are available within a manufacturing project.
Can you change the material or shape of an existing hat style?
Yes. An existing style can be the starting point for a manufacturing project. Share the material, shape, color or trim changes you have in mind so our team can discuss what is possible. Changes limited to logo, branding and packaging on an existing Dorfman style belong to our Private Label program.
Can we purchase design or sampling separately?
No. Design and sampling are part of a manufacturing project and are not offered as standalone services.
Let’s Make It Your Own
Bring us your inspiration, a sketch or a design ready for production. Tell us about your brand, the hat you want to create and your approximate quantities. We’ll help you explore the details and the next step.