Can I make a hat without a hat block?

I want to make a mini sinamay top hat, I've looked on the internet for information and think I'll be able to do it but would prefer not to use a hat block if possible- they're super expensive, and the polystyrene ones available are too big.

Oh, certainly, you can make your own. You are going to need some sort of form to work on. By itself, you can't get the shape you want.

You can make one out of styrofoam blocks. Sometimes you can find really dense foam they use for packing material around electronic pieces, like a computer or music players. You can also glue several pieces together for a larger shape. Cut it out to the way you want your hat... and then you are all set. These won't last for very long, but enough that you can make at least one or two pieces. Cover it with plastic wrap to keep it waterproof.

If you are talented with wood tools, you can make the same thing out of wood. That's what most hatters use. Of course, they need them for many, many hats.... are you going to make that many?

For rounded hats, you can use any round object, like a beach ball, a balloon, an up-turned bowl. In your case, you need a different shape.

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