The hat body then moves to the blocking stage, where the raw form is transformed into its primary silhouette. This critical step must be performed precisely to establish an accurate foundational structure.
During blocking, the hat body is clamped, steamed, stretched, and a specially shaped crown mold is gently pressed into the warm, pliable material.
The amount of steam, the degree of stretch, and the required time vary with the weight and type of felt; these parameters are determined by experience.
Next is decatizing, a slow, gentle process in which the hat bodies are “baked” in a chamber with steam and circulating hot air. This secondary treatment stabilizes and refines the shape and size, making them more exact and permanent.
After blocking and decatizing, the hat rests for several days so the fibers can relax and reach the appropriate humidity for surface finishing — even small differences in humidity can affect fine finishing work.
At this stage the piece graduates from a “hat body” to a finished “hat.”