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How a natural straw blade boater hat is made

Among boater hats, those made with natural straw blades are attractive for their texture and lightness. While taking advantage of the texture of the straw, the craftsmen's handiwork creates a beautiful silhouette. Here we will introduce the manufacturing process of boater hats made with natural straw blades.

1. Preparation of materials – Selecting straw carefully

The natural straw blades used for boater hats are mainly made from dried stalks of wheat or rye . To obtain good quality straw, the following conditions are important:

  • Straw that has grown straight : It is easy to trim it to a uniform width and creates beautiful weaves.

  • Strong fibers : Strong and increases the durability of the hat

  • Less uneven coloring : Natural golden color with a beautiful finish

The harvested straw is thoroughly dried in the sun and then steamed to keep it soft before being cut for the blades.

2. Making the braid – braiding the straw

The "braid" that forms the base of the hat is made by weaving natural straw into a long, thin ribbon. There are several different ways to weave it, but plain weave and twill weave are commonly used for boater hats.

The weaving is done by hand by artisans, carefully combining each strand of straw to create a uniform width. Because straw is a natural material, it will crack or tear if pulled too hard, so it is a delicate task that requires careful use of the right amount of force.

3. Sewing the blade – Assembling in a spiral

The braided blade is then sewn in a spiral pattern using a special sewing machine to create the shape of a hat.

Natural straw blades are a hard material that easily breaks, so sewing them requires advanced techniques. In particular, precise sewing is essential to create the flat crown and edgy shape that characterize the boater hat.

When sewing,

  • Align the blade joints so they are not noticeable

  • Stitch with uniform tension

  • Adjust the needle type and thread thickness to prevent the straw from tearing.

Such detailed ingenuity is required.

4. Forming (Blocking) – Use a mold to shape

The sewn hat body is then fitted into a wooden or metal mold made specifically for making boater hats, and the shape is adjusted by applying steam.

Natural straw is hygroscopic, so steaming it softens it and makes it easier to mold. During this process, particular attention should be paid to the following points:

  • Make the crown flat

  • Spread the brim at an even angle

  • Make the edges neatly at right angles

To create the crisp shape that is characteristic of boater hats, the hats are pressed into a mold and then dried.

5. Hardening treatment – ​​to achieve firm tension

Natural straw is relatively soft, so it goes through a hardening process to give it the hardness required for a boater hat.

Traditionally, natural starch glue or gelatin is used , which is spread evenly over the entire hat before drying. Nowadays, synthetic resins are sometimes used to increase the strength of the hat, but many craftsmen still use traditional techniques to preserve the natural texture of the materials.

The degree of hardening determines how hard the hat will be when it is finished and how well it will retain its shape.

6. Drying and finishing – making the details look beautiful

After the hardening process, the hat is dried for a certain period of time to set its shape firmly. After drying, the excess is cut off and the edges are smoothed.

In this process,

  • Make the brim lengths uniform

  • Reinforce the corners of the crown to prevent them from collapsing.

  • Check the overall balance

Adjustments such as these are made to complete the final form.

7. Decorations – Give your boater a unique look

What determines the impression of a straw hat is the ribbon and decorations wrapped around the crown.

Traditional boater hats usually have black or navy grosgrain ribbon , but patterned designs have become popular in recent times.

In addition, we sometimes use linen decorations to create a vintage feel.

8. Final check and finishing – the final step packed with the craftsman's attention to detail

The completed hats undergo a final check and are carefully finished down to the smallest detail.

  • Is there any loose stitching or misaligned threads?

  • Is there any unevenness in the hardening process?

  • Are the crown and brim angles even?

These points will be checked in detail and fine adjustments will be made.

Each straw hat is a unique piece.

The boater hats made from natural straw are one-of-a-kind items that make the most of the characteristics of the material . Even though they are made from the same straw, the appearance changes depending on the color and fineness of the fibers, and each one has a different texture.

Made using natural straw boater hats that are made using artisanal techniques and traditional methods, they are cool and light, and continue to be a beloved staple item for the summer.

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