These digital hat block files are made for hatters, hobbyists, and makers who want to build their own blocking setup without having to buy every block as a finished physical tool.
We started making our own blocks because proper hat-making tools can be expensive, hard to find, and difficult to collect when you are just getting started. These files are an even more affordable way to begin. You can print the blocks yourself, add sizes as you need them, and slowly build a useful set around the kind of hat work you actually do.
The shapes are designed for practical hat making, not just for display. They are meant for blocking felt hats, reshaping older hats, testing crown profiles, and building out a small shop setup one piece at a time. A proper block gives the crown something solid to form against, which makes shaping much more controlled than trying to do everything freehand.
Each file set includes printable hat block files based on the size, oval, and crown profile listed for that product. Different profiles create different crown shapes, so you can choose the blocks that best match the style of hats you want to make.
These are digital files only. No physical block will be shipped.
You will need access to a 3D printer and basic knowledge of slicing and printing large parts. Larger blocks may need to be printed in sections depending on your printer size.
For working hat blocks, PETG is the recommended starting material. It is tougher and more heat resistant than standard PLA, which makes it a better choice for tools that may be used around steam and moisture.
PLA or PLA+ can be used for test prints, display blocks, light shaping, or pattern checking, but I do not recommend it for regular steam work. Heat from steam can soften or distort PLA over time.
For heavier shop use, higher temperature materials such as ASA, ABS, nylon, or polycarbonate may be a better option if your printer is set up for them. These materials can handle heat better, but they are also more demanding to print.
Suggested starting settings:
0.2 mm to 0.28 mm layer height
4 to 6 walls
25% to 40% infill
Gyroid, cubic, or grid infill
5 or more top and bottom layers
Print with the base flat on the build plate when possible
These settings are only a starting point. Final strength, fit, and surface quality will depend on your printer, filament, slicer settings, bed adhesion, cooling, and calibration. Large parts may need slower print speeds, good bed adhesion, and careful cooling control to reduce warping.
Some layer lines or surface texture should be expected, but that is normal for printed hat-making tools. For the smoothest working surface, printed blocks can be lightly sanded after printing if needed.
These files are a good option if you are learning hat making, building your first tool set, replacing a missing size, or experimenting with different crown profiles without committing to a full set of physical blocks right away.
If you are not sure which size, oval, or profile you need, send me a message before ordering and I’ll help you choose the best option for your work.
These digital hat block files are made for hatters, hobbyists, and makers who want to build their own blocking setup without having to buy every block as a finished physical tool.
We started making our own blocks because proper hat-making tools can be expensive, hard to find, and difficult to collect when you are just getting started. These files are an even more affordable way to begin. You can print the blocks yourself, add sizes as you need them, and slowly build a useful set around the kind of hat work you actually do.
The shapes are designed for practical hat making, not just for display. They are meant for blocking felt hats, reshaping older hats, testing crown profiles, and building out a small shop setup one piece at a time. A proper block gives the crown something solid to form against, which makes shaping much more controlled than trying to do everything freehand.
Each file set includes printable hat block files based on the size, oval, and crown profile listed for that product. Different profiles create different crown shapes, so you can choose the blocks that best match the style of hats you want to make.
These are digital files only. No physical block will be shipped.
You will need access to a 3D printer and basic knowledge of slicing and printing large parts. Larger blocks may need to be printed in sections depending on your printer size.
For working hat blocks, PETG is the recommended starting material. It is tougher and more heat resistant than standard PLA, which makes it a better choice for tools that may be used around steam and moisture.
PLA or PLA+ can be used for test prints, display blocks, light shaping, or pattern checking, but I do not recommend it for regular steam work. Heat from steam can soften or distort PLA over time.
For heavier shop use, higher temperature materials such as ASA, ABS, nylon, or polycarbonate may be a better option if your printer is set up for them. These materials can handle heat better, but they are also more demanding to print.
Suggested starting settings:
0.2 mm to 0.28 mm layer height
4 to 6 walls
25% to 40% infill
Gyroid, cubic, or grid infill
5 or more top and bottom layers
Print with the base flat on the build plate when possible
These settings are only a starting point. Final strength, fit, and surface quality will depend on your printer, filament, slicer settings, bed adhesion, cooling, and calibration. Large parts may need slower print speeds, good bed adhesion, and careful cooling control to reduce warping.
Some layer lines or surface texture should be expected, but that is normal for printed hat-making tools. For the smoothest working surface, printed blocks can be lightly sanded after printing if needed.
These files are a good option if you are learning hat making, building your first tool set, replacing a missing size, or experimenting with different crown profiles without committing to a full set of physical blocks right away.
If you are not sure which size, oval, or profile you need, send me a message before ordering and I’ll help you choose the best option for your work.
