Once I come up with an image to produce, I do a general sketch which then gets inked and filled in with shadows and highlights. If an image will just be a silhouette cut out, the entire drawing is filled with black ink. I then digitize each drawing and set up the file to be recognized by a laser cutter. Once the image is cut out of thin wood veneer, a coat of stain is added followed by a weather protecting layer. The final image is then permanently adhered to each hat with a heat press.

The images that I create for the hats are digitized and cut out of thin wood veneer using a laser cutter. Once they are cut, I hand stain them before adding 3 coats of polyurethane for protection against water and sun. Some images are hand colored with color pencils to create a bolder look. The veneer is adhered to each hat by use of a hat heat press. A permanent heat activated adhesive is used to ensure the wood won't peel off. After lots of trial and error with the process and searching for the best, most flexible veneer, I finally obtained a product that is strong and durable that will last a very long time.