Stetson Hats: How It's Made and Shaped in Texas

When you hear cowboy hat, Stetson is the iconic American brand that springs to mind. The western hats aren't just functional workwear thanks to John B. Stetson's ingenuity, but have now come to represent the country way of life outside city limits. Stetson hats are so famous because they're well-made and made to last as they are one of the few products left that's truly made in the USA. The fur felt process happens at a separate factory and the straw hats are actually handwoven south of the border, but we had the opportunity to hit the open road and tour the place where all of the finishing touches come together in Garland, Texas. Here, HatCo manufactures hats for brands like Stetson, Resistol, and others. The Stetson hat factory process begins in the back of the warehouse where we watched how the western felt hats are made, with information on hat size and different hat styles. The straw cowboy hat production happens in another building across the parking lot, where we learned that each straw hat is woven by hand.

The best part of the factory tour, however, was learning about Stetson's history as a company and its many contributions to local museums around the country. More than just outdoor hat makers, the Stetson name is synonymous with the idea of the boss of the plains, a hat that will stand by you during a hard day's work out in the field. Though its wearers might get more use out of the felt cowboy hats on the dance floor than herding buffalo as cattlemen these days, the quality remains the same. Due to their wool felt process, water and moisture beads right off the hat, keeping you drier longer. The hat band carries the name of the quality control worker who gave your hat the final inspection, like Ms. Hazel we met in the video above.

The most popular models are the Stetson Rancher, the instant classic, while the Stetson Open Road is similar to the Rancher is one of the trendier hats in their glossary. This model is shorter, but smaller with a fedora style brim. Consider it a mini version! Every color from Acorn to Latte looks good, it just depends on what's in your closet already. The Stetson Skyline 6X Cowboy hat, the Stetson Bozeman, the Stetson Panama straw hat, the Stetson Silverbelly Rancher, the Stetson Airway, the Milan, and the Stratoliner are also popular models.

To find Stetsons in a store near you, check out Stetson hat company online, or visit your local retailers for different styles that vary from shop to shop. If you've never considered a Stetson before, but are now, don't be afraid to visit your local hatter to learn more. Hatmaking is an art form often left behind in the wake of new trends, so you can almost guarantee that your hatter would love to see their smiling face in that small room of their shop.

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