The Custom Hat Experience

Add 1cm to your head measurement to determine your correct hat size.

For example, a 57cm head measurement wears size 58 hat. 

The leather sweatband will gently mold to your head over time. Hats do not stretch.

Unsure about your measurement? Visit our Hat Sizing Guide for detailed measuring instructions and fit advice. Your size will be confirmed with you during your Virtual Design Session after purchase.

All sales are final. As each piece is handcrafted to order or produced in limited quantities, we are unable to offer returns or exchanges.

For detailed measuring guidance, refer to our Hat Sizing Guide. Your size and style are then confirmed during your Virtual Design Session before your hat goes into production.

Not confident on size or style? Chat with us before you order using the chat icon below.

Complete your Virtual Design Session with PHYLLi at the time of your order and your fit is guaranteed. In the event that your hat size or shape is not correct, PHYLLi will resize or reshape at no charge. Conditions apply.

Have a quick question about fit or style? Chat with us before you order using the chat icon below.

A private Virtual Design Session where you collaborate directly with hatmaker Laura Hall to design a one of a kind hat, handcrafted in our studio in regional Australia and made exclusively for you.

Yes. Each PHYLLi hat is handcrafted in our studio in regional Australia by hatmaker Laura Hall using premium western weight rabbit felt imported from Europe, or handwoven panama straw sourced from Ecuador.

Every PHYLLi hat is blocked, shaped and trimmed by hand by hatmaker Laura Hall in our studio in regional Australia. Each hat is made individually using time-honoured hat making practices, not mass produced in a warehouse.

The base price from $520-$590 includes your choice of premium felt or panama base, crown shape and brim width, classic ribbon band, 100% silk lining and leather sweatband, and personalised name stamping. Custom trims and specialty detailing are selected during your consultation and priced individually.

Most custom hats range between $750 and $1,200 depending on detailing. Custom trimmings range from $20 to $699.

Purchase your hat base, submit your consultation request via the Contact Form, and we will confirm your session. Trims and detailing are finalised during your 90 minute virtual appointment. Your hat is then handcrafted and delivered in a travel hat box.

Yes. All custom pieces are final sale. Production timelines are confirmed during your consultation.

Your hat should feel secure without pressure. Add 1cm to your head measurement to determine your size (eg. 57cm = size 58). The leather sweatband will gently mould to your head with wear. Hats do not stretch.

Unsure about your measurement? Visit our Hat Sizing Guide for detailed measuring instructions and fit advice.

Each hat is delivered in a travel hat box for protection and storage. For extended travel, we recommend using a purpose-designed travel case to protect the crown and brim.

PHYLLi hats are crafted from premium natural materials that reward proper care. Store your hat upright in the box provided, away from direct sunlight, heat, and pressure. For full care instructions, visit the Customer Care page.