Traditional Craft, Modern Quality

1. Crafted with Traditional Excellence

2. Handwoven with Precision

3. From Material to Masterpiece

4. Handcrafted Excellence Guaranteed

1. Crafted with Traditional Excellence

From hand-woven materials to steam shaping, each step reflects master craftsmanship

2. Handwoven with Precision

Using traditional weaving techniques, every hat is carefully crafted and meticulously finished

3. From Material to Masterpiece

Each hat undergoes complete hand-weaving, steam shaping, and precision pressing processes

4. Handcrafted Excellence Guaranteed

Selected natural materials go through weaving, shaping, and precision pressing to achieve perfect quality

Material Preparation

From the finest straw weavers in South America to our felt-makers in Europe, Lbora partners with artisans across the globe to source materials of exceptional quality, crafted exclusively for Lbora.

 

Every material is selected with a commitment to social responsibility, the preservation of traditional craftsmanship, and environmental sustainability.

 

When hat bodies arrive at our workshop, they are stored in a climate-controlled cellar. Production begins by choosing the perfect hat body in the correct size and color; it then undergoes a meticulous quality-control inspection before moving on to the blocking stage.

From the finest straw weavers in South America to our felt-makers in Europe, Lbora partners with artisans across the globe to source materials of exceptional quality, crafted exclusively for Lbora.

Every material is selected with a commitment to social responsibility, the preservation of traditional craftsmanship, and environmental sustainability.

When hat bodies arrive at our workshop, they are stored in a climate-controlled cellar. Production begins by choosing the perfect hat body in the correct size and color; it then undergoes a meticulous quality-control inspection before moving on to the blocking stage.
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Blocking

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.”

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.”
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Surface Finishing

Much of the hatmaker’s art takes place in the surface‑finishing room. Lbora’s skilled craftsmen use rare vintage tools and machines to pounce (shave), condition, and polish both the crown and brim of every smooth‑finish hat.

 

Other exotic finishes are achieved with specialized tools and processes tailored to produce unique textures and effects.

 

Different colors and weights of felt often require distinct treatments, even when the desired finish is the same.

 

A powerful dust‑extraction system removes most felt particles from the work area; all abrasive and dusty operations are performed in the surface‑finishing room.

 

After finishing, each hat is deep‑vacuumed using a purpose‑built machine from the 1940s that extracts minute felt residues from the hat’s pores.

 

Fine particles of dust can cause staining and can damage finely tuned sewing machines. To produce hats of Lbora’s quality, the workshop must remain immaculate.

 

Finally, every hat undergoes a thorough quality inspection before moving on to the next stage.

Much of the hatmaker’s art takes place in the surface‑finishing room. Lbora’s skilled craftsmen use rare vintage tools and machines to pounce (shave), condition, and polish both the crown and brim of every smooth‑finish hat.

Other exotic finishes are achieved with specialized tools and processes tailored to produce unique textures and effects.

Different colors and weights of felt often require distinct treatments, even when the desired finish is the same.

A powerful dust‑extraction system removes most felt particles from the work area; all abrasive and dusty operations are performed in the surface‑finishing room.

After finishing, each hat is deep‑vacuumed using a purpose‑built machine from the 1940s that extracts minute felt residues from the hat’s pores.

Fine particles of dust can cause staining and can damage finely tuned sewing machines. To produce hats of Lbora’s quality, the workshop must remain immaculate.

Finally, every hat undergoes a thorough quality inspection before moving on to the next stage.
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Trimming

Trimming includes installing the sweatband, lining, ribbon, and edge treatments.

 

After the sweatband is fitted and the brim trimmed, a fine grosgrain ribbon is formed into a bow and hand-sewn onto the hat. The inner lining, made of bridal satin, is also hand-stitched for both decoration and protection.

 

LBORA’s small team of trimmers has decades of combined experience and works closely with Graham on design and trimming. Their trained eyes and skilled hands produce exceptionally formed bows and precise edge stitching—the work of an experienced trimmer is clearly superior.

 

The workshop’s small scale balances output with artistry and gives the team full oversight of every production step. Bespoke orders allow clients to request unique ribbons and trims.

 

After trimming, the brims are shaped in a process called flanging.

Trimming includes installing the sweatband, lining, ribbon, and edge treatments.

After the sweatband is fitted and the brim trimmed, a fine grosgrain ribbon is formed into a bow and hand-sewn onto the hat. The inner lining, made of bridal satin, is also hand-stitched for both decoration and protection.

LBORA’s small team of trimmers has decades of combined experience and works closely with Graham on design and trimming. Their trained eyes and skilled hands produce exceptionally formed bows and precise edge stitching—the work of an experienced trimmer is clearly superior.

The workshop’s small scale balances output with artistry and gives the team full oversight of every production step. Bespoke orders allow clients to request unique ribbons and trims.

After trimming, the brims are shaped in a process called flanging.
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Material Preparation

Throughout finishing, hats undergo multiple procedures and continuous inspection to catch any flaws before delivery.

After trimming, each hat receives a final brim pressing (flanging), then the brim is buffed and the hat is either polished or brushed depending on the finish.

 

The hat is gently steamed, given a final inspection, and then packed into its hat box—every detail checked one last time.

As an optional finishing touch, many clients request a feather, usually tucked into the center of the bow. LBORA uses only natural, undyed feathers, hand‑assembled and tied in‑house.

Throughout finishing, hats undergo multiple procedures and continuous inspection to catch any flaws before delivery.

After trimming, each hat receives a final brim pressing (flanging), then the brim is buffed and the hat is either polished or brushed depending on the finish.

The hat is gently steamed, given a final inspection, and then packed into its hat box—every detail checked one last time.

As an optional finishing touch, many clients request a feather, usually tucked into the center of the bow. LBORA uses only natural, undyed feathers, hand‑assembled and tied in‑house.
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