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HANDCRAFTING AN AKUBRA
The Making Of An Icon
Every Akubra hat is the result of a meticulous, time-honoured craft. Made in Australia for 150 years using a 162-step hat making process, each hat is shaped through generations of expertise and traditional techniques.
From the early stages of forming and blocking the fur felt through to trimming and finishing, every step contributes to the durability, character and iconic style that Akubra hats are known for.
Discover ten of the key stages in the Akubra hat making process that bring an Akubra hat to life.
Crafting Stage I
Fur Preparation
Every Akubra starts with carefully prepared rabbit fur. Once delivered, the fibres are selected and blended to achieve the colour the hat will become later in the process.
Lighter fibres for pale shades, deeper greys for darker tones. The fur is then cleaned using specialised machinery to remove dust and impurities, ensuring only the finest fibres move on to the next stage of hat-making.
This is where the 162-step journey begins.
Crafting Stage II
Body Formation
From fur to form, this beginning stage of the body manufacturing process starts with a cone or body that is nearly three times the size of the finished hat. Over the next fourteen days, it is carefully shaped and refined, gradually taking form.
Along the way, it’ll pass through at least 15 pairs of skilled hands, each playing a role in bringing an Akubra to life.
THEN VS NOW
Use the left and right arrow keys to navigate between before and after photos.
Crafting Stage III
Felting
Once the cone is formed, the felt undergoes a carefully controlled felting process. Using heat, moisture, and pressure, the fibres shrink, interlock, and condense, transforming loose rabbit fur into a dense, resilient material.
This step is integral to the hat’s strength and structure, and it’s what gives an Akubra the durability to last a lifetime.
Crafting Stage IV
Felt Bumping
After the felt is formed and initially condensed, it enters the bumping stage, a traditional step that further strengthens and refines the material. In this part of the process, the felt body is worked with heat and moisture, passing through specialised bumping machinery that helps short fibres bind into the surface and consolidates the texture.
This makes the felt denser, smoother and more resilient, setting it up for shrinking, shaping and finishing. It’s one of the many essential touches in the Akubra‑making process that contributes to its iconic durability and quality.
Crafting Stage V
Dye House
Once the felt body has been formed and condensed, it enters the dye house, a meticulous stage where the iconic Akubra colours are brought to life. Individual shades are mixed and weighed by hand. Some classic hues have been mixed and their recipes carefully maintained for decades.
The felt is then immersed in a heated dye bath, allowing colour to penetrate evenly through the dense material. After dyeing, the body is passed back through rollers to help set the colour and prepare the felt for its next stages of shaping and finishing. This process ensures every Akubra carries a consistent, rich shade that can endure the rigours of time and use.
Crafting Stage VI
Blocking the Body
Once the felt has been dyed, it moves into the blocking stage, a crucial step in defining the hat’s silhouette. The damp, pliable felt is placed over a shaped wooden or metal hat block, and steamed or stretched so it conforms precisely to the desired crown and brim profile of the style. Using heat, moisture and pressure to mould the felt, our Master Hatters then ensure the curves, angles, and dimensions are correct.
Though the tools and techniques have evolved slightly, the essence of blocking is a traditional millinery craft that has stood the test of time over.
Crafting Stage VII
Sanding the Body
After blocking, the hat body moves into sanding (or pouncing), where the felt surface is smoothed and stray fibres removed. Using fine abrasives and specialised sanding machinery, the texture is refined, making the felt softer to the touch and ready for trimming and finishing.
While machinery may have evolved since 1876, the essence of this surface refinement step has remained unchanged for generations, giving every Akubra its polished, durable finish.
Crafting Stage VIII
Polishing the Body
After sanding, the hat enters the polishing stage, where it is gently brushed and buffed to refine the texture, deepen the colour, and remove any remaining loose fibres. Specialised polishing wheels and brushes ensure a smooth, consistent finish.
This step unifies the texture, deepens the colour, and gives the felt a smooth, refined finish that feels as good as it looks.
Crafting Stage IX
Shaping of an Icon
Once the felt body has been polished, it moves into the shaping stage, where it begins to take on its iconic finished form. In this step, the hat is carefully stretched and moulded over a blocking form (precreasing mould) to define the precise crown profile and brim curve. Our Master Hatters’ skilled hands use a combination of heat, tension and specialised shaping tools to ensure every angle and proportion is correct and consistent with the intended style.
Although some machinery assists with shaping, much of the process relies on the hatter’s touch and judgement, a blend of tradition, instinct and technique that has been passed down in our Workshop over 150 years.
Crafting Stage X
Signature Finish of an Icon
In the trim shop, the signature finishing touches on an Akubra that give it character and polish come to life. Leather sweatbands are added through a meticulous multi-step process, while the crown may be adorned with eyelets, hat bands, and brim binding. These details refine the silhouette, improve comfort, and bring the hat to life. Finally, each hat is lined or tipped with a stamp to mark its origin of completion.
After this final stage, the hat undergoes a thorough quality check, ensuring every Akubra is ready for years of wear and adventure.
