Our USA Factory – Larry Mahan Hats

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Five stacked white hat bodies on a wooden table as a white brush's bristles rests on top of the stack with a piece of chalk and black sponge off to the right side

Our Process

The Making of Larry Mahan Hats

Established in 1983 in Garland Texas, Larry Mahan applies time-honored craftsmanship to create handmade hats of unmatched quality, fit, comfort, and style. At nearly every stage of our hat making process, we depend on skilled hands to carry out centuries-old techniques with precision.

Stacks of dark red hat bodies in the background of a white stack of hat bodies

Step 1

Select premium raw hat body

Black hat with steam rising up into it while a man with blue gloves holds it up to a machine's spout

Step 2

Steam to activate fibers

Man with blue gloves and black apron pressing a hat block into the underside of a black hat

Step 3

Block correct size

Black and silver colored machine with yellow tubes coming out of the top pressing a hat block into the underside of a hat

Step 4

Press the crown

White hat brim being sanded down by a woman with black gloves as fabric bits flies off to the right

Step 5 & 6

Bevel edge and smooth crown

White plain hat being sanded against a sanding machine held against by a person wearing black gloves

Step 7

Brim sanding

Woman adding pastel coloring to an upside down white hat with a cloth

Step 8

Add pastel coloring

Woman with pastel covered hands forming the shape of a brim on a white hat

Step 9 & 10

Shape brim and crown profile

Machine applying a gold strand material to the brim of a hat to add the color coloring to the edges and printed text while a hand holds it in place

Step 11

Add custom leather fit

Woman's hands holding a white hat to use a machine to stitch a tan band to the underside of it

Step 12

Stitch interior sweatband

Woman using a machine to stitch a size label to the leather strap of a hat

Step 13

Leather sew sizing

Woman tacking a black band onto the top of a white hat

Step 14

Tack the band

Woman inserting a brown lining to the underside of a white hat

Step 15

Insert lining

Woman wearing a black apron and shirt holding a white cowboy hat against a hat rack as she inspects each of them row by row

Step 16

Pass inspection

Step 17

Final touches

Closeup photo of the Larry Mahan 1000X dark brown box with gold lettering and ribbon