Custom Cowboy Hat — Toyo Straw with Yarn Dyeing
We supply cowboy hat to brands, retailers, uniform and promotional programmes, made in Toyo Straw with yarn dyeing for bridal and eveningwear studios. On headwear the specification that decides whether it sells or comes back is brim roll, which has to hold and still be shapeable — so that is agreed in writing before bulk, not discovered when the first carton is unpacked. Programmes start at 3000 pieces per style.
The failures here are predictable: colour drift between the approved sample and the bulk trim, or a supplier who disappears once the deposit is paid. We lock material, construction, measurement and tolerance on a pre-production sample, and prepare UKCA and REACH documentation so the container clears instead of missing the season it was bought for.
Specification
| Product | Cowboy Hat |
|---|---|
| Crown | 4 inch crown |
| Type | wool felt cowboy hat |
| Material | Toyo Straw |
| Construction / finish | Yarn Dyeing |
| Colour options | 12 shades, Pantone matched |
| Packing | bulk carton |
| MOQ | 3000 pieces per style |
| Sampling | 12 working days, 5 days per revision |
| Bulk lead time | 25-30 days after approval |
| Compliance | UKCA and REACH documentation; EN 71 part 3 for decorative components |
| Ship to | Felixstowe (the United Kingdom) |
What buyers can customise
- Sandwich Brim — available on Toyo Straw, quoted per position and per colour.
- Powder Coating — available on Toyo Straw, quoted per position and per colour.
- Edge Binding — available on Toyo Straw, quoted per position and per colour.
- Yarn Dyeing — available on Toyo Straw, quoted per position and per colour.
- Hand Crochet — available on Toyo Straw, quoted per position and per colour.
- Structured Front Panel — available on Toyo Straw, quoted per position and per colour.
- Knitted Structure — available on Toyo Straw, quoted per position and per colour.
How we produce it
- Specification review — shape, measurement, material and target price
- Material sourcing and a finished sample in the agreed Toyo Straw
- Shape sample with yarn dyeing applied, blocked or knitted to the approved profile
- Wear and wash test on the production material, then pre-production sample
- Bulk production with in-line checks on shape, stitching and trim alignment
- Final AQL 2.5 inspection and packing that protects the shape in transit
Where it sells
- Retail chains and department stores — repeatable spec, stable reorders
- E-commerce and small-batch brands — low minimums across many designs
- Uniform and corporate programmes — held spec for years of repeat orders
- Promotional and event channels — logo application and retail packing
- Outdoor and winter programmes — built for the climate it is sold in
Packing, testing and delivery
Pieces are packed to the ratio you specify — by size, by colour or by style set — with barcodes applied where the channel needs them, and shape-protected where the profile cannot be crushed. Test reports for EN 71 part 3 for decorative components are prepared for the destination market. We ship to Felixstowe with invoice, packing list and certificate of origin, and keep the approved reference on file so reorders reproduce the same material, the same construction and the same brim roll.
FAQ
What is the minimum order?
Programmes start at 3000 pieces per style per finish. Mixed sizes are fine within one style.
Can you match a reference sample?
Yes. Send the trim and we match material, finish and shade, then confirm on a pre-production sample before bulk.
Can you do small runs across many designs?
Yes — many studio and boutique programmes run small quantities across a wide design set.
Which compliance documents do you provide?
We prepare EN 71 part 3 for decorative components and the supporting test reports for the destination market.
Start your cowboy hat programme
Send us a reference sample, a drawing or a spec sheet and we will come back with material options, a costing and a sampling timetable.
