Key Responsibilities and Required Skills for Hat Maker

🎯 Role Definition

We are hiring a professional Hat Maker (Milliner) to design, craft and repair bespoke and small-batch hats and headpieces for retail, bridal and couture clients. The ideal candidate combines advanced millinery techniques (blocking, pattern development, hand-sewing and trimming), strong materials knowledge, and excellent client-facing skills to deliver high-quality, well-fit hats on schedule. This role supports product development, production scaling, in-store fittings and occasional event or runway work.

📈 Career Progression

Typical Career Path

Entry Point From:

Millinery Apprentice or Millinery Assistant
Seamstress / Tailor with headwear experience
Costume Maker or Wardrobe Technician

Advancement To:

Senior Milliner / Head Milliner
Head of Accessories Design (Hats & Headwear)
Production Manager (Millinery/Accessories)

Lateral Moves:

Costume Designer / Theatrical Wardrobe Lead
Bridal / Couture Headwear Specialist

Core Responsibilities

Primary Functions

Design and develop original hat and headpiece concepts for bespoke clients, bridal parties, retail collections and editorial or runway projects, producing clear sketches and technical specifications that align with brand standards and client briefs.
Translate design sketches into accurate paper patterns and full-size templates, iterating patterns to achieve optimal fit and proportion for a variety of head shapes and styles.
Block and shape hat forms using wood, metal or plastic blocks and steam/heat techniques to create consistent, repeatable silhouettes for both one-off and small-batch production.
Execute precise cutting of felts, straw, buckram, fabric and other millinery materials, ensuring grain, yield and material waste reduction are managed effectively.
Hand-stitch and machine-sew components using specialized techniques (invisible stitch, ladder stitch, slip stitch) required for high-end couture hat construction and durable production-level items.
Construct structured hats including shaping crowns, brims and internal sweatbands, installing liners, interfacings, buckram and support structures to meet design and durability requirements.
Apply trims, bows, veils, feathers, sinamay manipulation, ribbonwork and other embellishments with couture-level finishing, including hand-blocked shape retention and secure attachment.
Fit and alter hats during client fittings, accurately measuring head circumference, crown height and balance, making real-time pattern and form adjustments to ensure exceptional fit and comfort.
Repair, restyle and refurbish vintage or damaged hats, applying historical millinery techniques where appropriate to preserve original integrity while restoring function and aesthetics.
Advise clients and merchandisers on material selection, color matching and trim options, translating technical constraints and cost implications into practical recommendations.
Source and manage inventory of specialty millinery supplies (blocks, buckram, sinamay, stiffeners, feathers, veils, trims), negotiating with suppliers to secure quality materials at competitive prices.
Prepare prototypes, samples and production-ready specifications for seasonal collections, collaborating cross-functionally with design, production and merchandising teams to meet launch timelines.
Supervise or mentor junior milliners and apprentices, setting standards for finishing, quality control and workshop safety, and providing hands-on coaching in blocking, patterning and trimming techniques.
Operate and maintain millinery equipment including steamers, sewing machines (industrial and domestics), blocking tools, hat presses and hand tools, ensuring cleanliness, safety and calibration.
Maintain accurate work orders, production logs, sample records and client alteration histories to support traceability and repeatability in bespoke and custom orders.
Estimate labor and material costs for bespoke commissions and small-batch production, preparing quotes and contributing to pricing strategies that reflect craftsmanship and overheads.
Meet production deadlines for bridal, event and retail orders, coordinating with production planners to manage lead times, rush orders and priority deliveries.
Implement and enforce workshop health and safety procedures when working with steam, dyes, sharp tools and sewing equipment, including appropriate PPE and safe material handling.
Contribute to visual merchandising of hats in-store and online by advising on display techniques, photographing product for ecommerce and ensuring finished goods present to retail standards.
Collaborate with external designers, stylists and costume departments on commissioned pieces for editorial shoots, theatre, film and special events, adapting techniques to scale and creative direction.
Continuously research millinery trends, historical techniques and new materials or technologies (e.g., laser cutting, digital patterning) to recommend innovations and improvements in product development.
Troubleshoot construction or fit issues during production runs, implementing root-cause fixes to tooling, patterns or sewing processes to reduce rework and scrap rates.
Ensure compliance with product safety regulations, labeling requirements and export documentation where applicable for materials such as treated feathers or restricted trims.

Secondary Functions

Provide in-store or studio consultations and fittings, nurturing client relationships to drive repeat business and referrals for bespoke and special-event orders.
Support small-batch production planning by assisting with scheduling, material requisitions and quality checkpoints during sample and production runs.
Participate in photoshoots and marketing initiatives by preparing hats to brand presentation standards and advising on styling for social media and ecommerce imagery.
Train retail staff on hat care, basic fitting and product storytelling to improve conversion and post-sale satisfaction.
Assist with inventory counts, receiving shipments and organizing storage of blocks, trims and fragile materials to minimize damage and loss.
Help prepare costed proposals and written estimates for custom commissions, communicating turnaround times, deposit requirements and alterations policy.
Participate in pop-up events, trunk shows and trade fairs to represent the millinery offering, demonstrate craft techniques and provide on-the-spot fittings or repairs.
Document and archive digital and physical sample files, including photographs, pattern files and material swatches, to maintain a searchable reference library for future projects.

Required Skills & Competencies

Hard Skills (Technical)

Advanced millinery techniques: hat blocking, crown and brim shaping, blocking restoration and retaining shape through steam manipulation.
Pattern drafting and alteration specifically for headwear, including creating slopers, scaling patterns and grading for multiple sizes.
Expert hand-sewing skills and couture finishing stitches (slip stitch, whip stitch, ladder stitch, catch stitch) for invisible joins and trim application.
Proficiency with industrial and domestic sewing machines relevant to hat construction (zig-zag, straight-stitch, overlock) and the ability to troubleshoot basic mechanical issues.
Material expertise: felts (wool, rabbit), straw types, sinamay, buckram, felt stiffeners, leather sweatbands, veiling, and feather treatments.
Trim and embellishment application: ribbon work, millinery wire, veils, bows, flowers, feather blocking and wiring techniques.
Experience in bespoke fittings, measurement techniques, and making real-time adjustments to patterns and blocks during customer appointments.
Sample making and small-batch production setup: creating production-ready prototypes, component lists and quality standards for hand-made lines.
Basic costing and quotation skills for bespoke orders, including labor hour estimation, material costing and markup calculation.
Workshop equipment operation: steamers, hat presses, blocking irons, glove stiffeners and safe use of adhesives and fabric dyes.
Familiarity with health and safety procedures and regulations related to workshop environments and handling treated natural materials.
Basic digital design skills (optional but advantageous): Adobe Illustrator or similar for flat sketches, digital pattern annotations and tech packs.

Soft Skills

Exceptional attention to detail and a commitment to couture-level finish and fit.
Strong client service and communication skills for consultations, fittings and post-sale care.
Creativity and aesthetic sensibility with the ability to interpret briefs and propose visually compelling concepts.
Time management and the ability to prioritize multiple bespoke commissions and production deadlines.
Problem-solving mindset to adapt construction methods for challenging designs or materials.
Patience and teaching ability when mentoring apprentices or educating retail staff.
Team collaboration skills to work across design, production and retail teams.
Resilience and adaptability in a fast-paced studio environment with fluctuating workloads.
Professional presentation and storytelling skills to communicate product value and craftsmanship to customers and buyers.

Education & Experience

Educational Background

Minimum Education:

High school diploma or equivalent; vocational training or certificate in millinery, fashion design, textile arts, costume construction or related craft recommended.

Preferred Education:

Certificate or diploma in Millinery / Millinery Apprenticeship, Fashion Accessories Design, or a degree in Fashion Design with accessory specialization.
Coursework or short courses in traditional millinery techniques, pattern making, textile science or couture finishing.

Relevant Fields of Study:

Millinery / Hat Making
Fashion Design and Accessories
Textile Science / Surface Design
Costume Design / Costume Construction

Experience Requirements

Typical Experience Range: 2–8 years of hands-on millinery experience, depending on role level (junior to senior).

Preferred:

3+ years of professional experience for mid-level positions, including experience with bespoke commissions, client fittings and small-scale production.
5+ years for senior or head milliner roles with demonstrated leadership, sample-to-production oversight and mentorship experience.
Experience in bridal, couture, theatre or film millinery considered highly desirable.