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Made To Order

Made To Order

Crafted just for you.

Each hat is individually handcrafted in regional Australia once your order is placed. Select your size and style, and we’ll create a hat designed to last a lifetime.

An intentional alternative to mass production.

Made to order in 3 - 4 weeks, delivered in a travel hat box.

51 products

Caramel cowboy hat The PHYLLi Caramel by PHYLLi Designs with Buffalo Girl Western floral tie back hat band and fallen feather bunch.
The PHYLLi Caramel Sale price$945
Front view of black felt hat with medium brim and paint-speckled decorative band by PHYLLi Designs on a white background.
The Painter Sale price$755
Front view of Santa Monica Lilac felt hat by PHYLLi Designs with rust Japanese grosgrain band, oil green bow and sari silk trim.
Santa Monica Lilac Sale price$755
Barbados Rose rose felt hat by PHYLLi Designs with distressed turmeric Japanese grosgrain band, rust bow and candy and rose sari silk trimming.
Barbados Rose Sale price$755
The Sailer havana brown felt hat with telescope crown, silk twine trim and hat pin by PHYLLi Designs on a light background.
The Sailer Sale price$709
Front view of the Fly Fisher Havana felt hat by PHYLLi Designs with praline grosgrain band and sari silk trim.
Fly Fisher Havana Sale price$709
Pamela spiced pumpkin felt hat by PHYLLi Designs with sherbet pink Japanese grosgrain band and watermelon bow.
Pamela Sale price$709
Marrakech spiced pumpkin felt hat by PHYLLi Designs with distressed praline Japanese grosgrain ribbon band and black brim trim.
Marrakech Sale price$709
Australis caramel felt hat by PHYLLi Designs with sand Japanese grosgrain double bow band and ballerina pink sari silk trim.
Australis Sale price$709
Spiced Pumpkin felt cowboy hat Evans by PHYLLi Designs with plaited sari silk trimming in salmon, cream and blush.
Evans Sale price$709
Diamonds & Pearls eucalyptus felt hat by PHYLLi Designs with sherbet pink Japanese grosgrain band, cream sari silk trim and pearl charm hat pin.
Diamonds & Pearls Sale price$679
Kentucky rose felt hat by PHYLLi Designs with distressed ivory Japanese grosgrain bow band and peach and pale blue sari silk trimming.
Kentucky Sale price$679
Calaveras caramel felt hat by PHYLLi Designs with chocolate Japanese grosgrain double bow band and skull bead cluster.
Calaveras Sale price$679
The Rider havana brown felt hat with vintage grosgrain bow band, distressed brim trim and feather detail by PHYLLi Designs.
The Rider Sale price$675
Jersey caramel felt cowboy hat by PHYLLi Designs with distressed black Japanese grosgrain ribbon band and black sari silk trim.
Jersey Sale price$675
Front view of The Betty black felt hat by PHYLLi Designs with black Japanese grosgrain bow band and burgundy distressed patch detailing.
The Betty Sale price$665
Front view of black felt hat with decorative band and pencil curl brim by PHYLLi Designs on a light grey background.
The Rocker Sale price$659
Front view of The Fall eucalyptus felt hat by PHYLLi Designs with natural linen band and twine trim.
The Fall Sale price$655
Howlit Spiced Pumpkin felt hat by PHYLLi Designs with apricot Japanese grosgrain band, cornflower bow, and plaited twine trim with turquoise stones.
Howlit Sale price$655
Front view of black felt cowboy hat by PHYLLi Designs on a white background.
The Urban Cowboy Sale price$655
Spiced Pumpkin felt hat Flax by PHYLLi Designs with natural linen bow band.
Flax Sale price$645
Spiced pumpkin felt hat Pumpkin Bloom by PHYLLi Designs with distressed dirty rose Japanese grosgrain bow band and sari silk lapel bloom.
Pumpkin Bloom Sale price$639
Roadie Panama natural straw hat by PHYLLi Designs with distressed Japanese grosgrain ribbon band in rust, copper, turmeric and taupe.
Roadie Panama Sale price$619
My Magical Natural Panama hat by PHYLLi Designs with distressed ivory Japanese grosgrain bow band, plaited sari silk trim and burnt branded palm trees, waves and boat.
My Magical Hat Sale price$619
Producer wide-brim felt hat in spiced pumpkin with sand band by PHYLLi Designs on a light grey background.
The Producer Sale price$619
The Open Road caramel felt hat with Open Road cowboy crown and black grosgrain band with grey darning patches by PHYLLi Designs.
The Open Road Sale price$619
Maple caramel felt hat by PHYLLi Designs with copper Japanese grosgrain bow band and bronze crown chain with leaf charms.
Maple Sale price$619
Front view of The Wisteria lilac felt hat by PHYLLi Designs with ivory grosgrain band and sari silk trim.
The Wisteria Sale price$615
Santa Monica Panama hat in Biscuit with Rust distressed grosgrain band, Oil Green bow and Rose sari silk trim.
Santa Monica Panama Sale price$569
Malibu Panama hat with distressed Copper grosgrain band, Rose bow and speckled Cream and Marigold sari silk trim.
Malibu Panama Sale price$569
Barbados Panama hat in Biscuit by PHYLLi Designs with copper grosgrain band and rose sari silk trim.
Barbados Sale price$569
Blue Jean Natural Panama hat by PHYLLi Designs with dark navy Japanese grosgrain bow band, plaited sari silk trim in ivory, olive and teal and silver chunky hat pin.
Blue Jean Sale price$569
Natural Panama straw hat Delfina by PHYLLi Designs with cornflower and bubblegum tie dye sari silk trimming.
Delfina Sale price$569
Female model wearing the black felt cowboy hat B&W Wheeler by PHYLLi Designs with black Japanese grosgrain band in a rustic countryside setting.
B&W Wheeler Sale price$569
PHYLLi Designs The Plains black felt cowboy hat in western weight rabbit felt with black Japanese grosgrain double bow band.
The Plains Black Sale price$569
Fly Fisher Panama biscuit Panama hat by PHYLLi Designs with chocolate Japanese grosgrain band, dark brown brim trim and speckled sari silk trimming.
Fly Fisher Panama Sale price$539
Santa Fe Winter Panama biscuit Panama hat by PHYLLi Designs with teal, storm blue and smoke sari silk trimming.
Santa Fe Winter Panama Sale price$539
Normie Panama hat in Biscuit with distressed Taupe grosgrain band, Chocolate bow and bronze crown chain.
Normie Panama Sale price$539
Nim Panama biscuit Panama hat by PHYLLi Designs with oil green Japanese grosgrain bow band, sari silk trimming and tan suede string.
Nim Panama Sale price$539
Mango natural Panama hat by PHYLLi Designs with distressed copper Japanese grosgrain bow band and twine wrap with rainbow disc clusters.
Mango Panama Sale price$539
Isle of Skye natural Panama hat by PHYLLi Designs with oil green Japanese grosgrain bow band and rose quartz hat necklace.
Isle of Skye Sale price$539
Calipso Panama hat in Natural handwoven toquilla straw with Sand Japanese grosgrain band and Melon sari silk trim.
Calipso Sale price$539
Hunter Panama hat with Cornflower Japanese grosgrain band, Oil Green bow and Cream and Blue sari silk trim.
Hunter Panama Sale price$539
Sunset Panama natural Panama hat by PHYLLi Designs with apricot, dusty pink and rust sari silk trimming.
Sunset Panama Sale price$539
Isle of Skye 2.0 Natural Panama hat by PHYLLi Designs with oil green Japanese grosgrain bow band, mint sari silk trim and rose quartz crystal clusters.
Isle of Skye 2.0 Sale price$539
La Journee Natural Panama hat by PHYLLi Designs with cement Japanese grosgrain band, storm sari silk trim and smokey quartz crystal clusters.
La Journée Panama Sale price$539
Taupetone Biscuit Panama hat by PHYLLi Designs with taupe Japanese grosgrain band, sand bow, nude sari silk trim and plaited suede string.
Taupetone Sale price$539
Natural Panama hat Figueras by PHYLLi Designs with dark navy Japanese grosgrain bow band.
Figueras Sale price$539

Handcrafted Hats Ready When You Are

Each PHYLLi hat is handcrafted in regional Australia by hatmaker Laura Hall, using traditional hatmaking techniques and carefully sourced materials. Whether selecting a ready-to-ship design or commissioning a made-to-order piece, every hat is created to balance craftsmanship with modern wearability.

Designed to be Worn for Years to Come

PHYLLi hats are created as enduring wardrobe pieces rather than seasonal accessories. Carefully shaped silhouettes, premium materials and signature trims ensure each design becomes a long-term staple, worn for everyday style, travel and special occasions.

Explore the PHYLLi Hat Collection

Discover Ready To Ship Hats, Pre-Order Hats, Made To Order Hats and Limited Edition Hats within the full PHYLLi hat collection, where each handcrafted design reflects Laura Hall's modern approach to Australian hatmaking.