Making hats for ballet

Just this week I made a hat for a dancer sight unseen.  When making a headpiece or any costume item choosing the right materials and colors is very important. The hat I was making was going to be brown with cranberry colored flowers. Sounds easy, no? but what is cranberry or even brown for that matter? Here is just a small example of shades of cranberry:

 If we are really honest though, color choices are much more like this; just look at the bottom row for "brown":

Since I did not have any fabric swatches I just guessed and made what I thought looked good; a bit risky but I figured if it looked pretty and had several shades, even if it wasn't a perfect match it would still look good. A good way to help with choosing colors and being on the same page when it comes to talking about colors  is to go to the paint store and select some of those chips.
Due to time constraints I had to go with what I had available so I dug into my stash and found some lovely velvets and some lilac and "cranberry" red silk. The dancer and I decided on the brown velvet for the hat base and then I came up with the idea to take silk organza and dye it several shades of "cranberry".

Fabrics from stash

 The next challenge for a ballet hat was its design.

Brown velvet, wired buckram shape and cranberry silk organza for the flowers.

No one wants a hat to fall off but on a dancer staying on your head is a minimal requirement not just "would be nice". A ballet hat has to be fairly strong too. A while back I purchased an e-book from Prudence millenry to help me learn how to make couture flowers and headbands. Using the methods describe there I made a frame of wire and buckram, covered it with some flannel and then applied the velvet. The book called for ice-wool, a short of wool knit batting but that is very hard to find and expensive so I substituted flannel as the flalene. I then dyed horsehair (a nylon, millenry mesh braid which is very strong but will blend into the dancers hair) and some mesh elastic and sewed that onto the bottom of the hat.
The flowers were made by hand, using bias cut tubing and hand cut petals. I also made some Yo-yo style daisies and sewed glass beads into the center to simulate stamens.
Although there are specialize sewing machines to sew hats, you can use a regular machine, I ended up sewing everything by hand to get the tight, clean finish I wanted. The book also shows that to get the best results, the hat shape should be hand sewn.

Hat after blocking

I then blocked and shaped the hat form. To do this I pinned the shape to a foam head and using steam, which softened the glue in the buckram, I reshaped it. Once the hat cools down, the buckram stiffens up again so that the hat keeps it shape. The horsehair on the bottom of the hat and the mesh elastic strap (which runs along the back of the head at the base of the skull) allows the hat to be pinned all around so it will not come off.

Close up of the flowers and hat.

I was happy with the completed hat and after testing it (sounds silly but I feel an once of prevention is worth it), it was packed up and sent off. Another busy week but certainly not dull!