The roots of Gem Hats extend further than our launch in 2021. And those roots are still impacting our approach to sustainable hat making today.
When Caroline was living in Mexico City, she fell in love with the street markets. Bolts of fabric that nobody wanted. Scraps of silk left over from other projects. Leather pieces trimmed off and tossed aside.
She didn't see those as scraps with no more life. She saw them as gems, pieces that could still be used in the beautiful art of hat making. While learning the craft from locals, she started imagining ways to use those leftovers for a real purpose.
When she moved to Denver and launched Gem Hats, that instinct came with her. Using upcycled materials wasn't a sustainability strategy she developed later. It was baked into the idea from the very beginning. It's how the whole thing started.
Today, when you sit down at our custom hat bar, the bands and trims you choose from are made from those same kinds of materials: scrap leather sourced locally, silk reclaimed from a trusted textile supplier, and other repurposed finds that give your hat a story before you've even started designing it.
Key Takeaways
At Gem Hats, more than 80% of our design materials are upcycled or repurposed. We source scrap leather from local Denver suppliers and reclaimed silk from trusted partners, materials that would otherwise end up in a landfill. The result is a hat band that no one else in the world has. Here's the story behind why we made that choice from day one, and why it matters for the hat you walk out wearing.
Table of Contents
- What Are Upcycled Materials?
- The Fashion Industry's Waste Problem Is Real
- Where Our Upcycled Leather and Silk Actually Come From
- How Upcycled Materials Make Your Hat Truly One of a Kind
- Does Upcycled Mean Lower Quality
- Ready to Make Your Own Upcycled Piece?
- Frequently Asked Questions
What Are Upcycled Materials?
Upcycled means taking an existing material and giving it a higher, better use than it had before, without breaking it down first. It's different from recycling. Recycling typically involves breaking a material apart and reprocessing it into something new. Upcycling skips that step and transforms what already exists into something meaningful.
In fashion, this usually means turning leftover or discarded textiles into new garments or accessories. For us, it means taking scrap leather and offcuts of silk that would otherwise be thrown away, and turning them into hat bands that become the most personal part of your hat.
The upcycled fashion market is growing fast, currently valued at nearly $9 billion globally and projected to nearly double by 2032. Consumers are catching on to what makers have known for years: materials with a previous life often have more character than anything new.
One thing upcycled doesn't mean is low-quality or haphazard. We're not grabbing random scraps and hoping for the best. Every material we work with is sourced intentionally, chosen for texture, durability, and how it will look and wear on a hat.
The Fashion Industry's Waste Problem Is Real
The global fashion industry produces around 92 million tons of textile waste every year. That's roughly a garbage truck full of clothing and fabric hitting a landfill every single second.
In the United States, about 85% of all textiles end up in landfills annually. Less than 15% are recycled. The rest sit there for decades, or longer, since synthetic fibers can take hundreds of years to break down.
We're not a fashion brand that produces at scale. But we do believe that the choices small businesses make add up. When we source scrap leather instead of buying new, that leather doesn't go into the trash. When we use offcut silk instead of ordering fresh yardage, we're not adding to the demand for new production. It's a small act in a big problem, but it's a genuine one.
Upcycling reduces the environmental footprint of fashion by keeping textiles out of landfills and cutting demand for raw materials. For us, it also just makes sense creatively. The best materials we've ever worked with came from somewhere unexpected.
Where Our Upcycled Leather and Silk Actually Come From
Our upcycled hat band materials come from two main sources: local leather suppliers here in Denver and a trusted silk supplier we've worked with for years.
The leather comes from scrap and offcut pieces, the leftover material from other leather goods production. Instead of going to waste, those pieces come to us and get cut into hat bands. Because every scrap is different in texture, grain, and tone, every leather band we make is slightly different from the last.
The silk works the same way. Our supplier provides us with offcut and surplus silk that would otherwise be discarded. We sort through it, choose pieces that work for hat bands, and incorporate them into the selection you'll browse when you come in for your appointment.
If you want to see exactly how these materials get worked into a finished hat, our post on the cowboy hat shaping process walks through the whole thing from material selection to the final band and branding.
How Upcycled Materials Make Your Hat Truly One of a Kind
Because no two scraps of leather or silk are identical, no two Gem Hats bands are the same. That's not a side effect of using upcycled materials, it's the whole point.
When you choose a hat band from our selection, you're choosing a piece of material that exists once. The grain pattern, the color variation, the texture — those are specific to that piece of leather or silk, and now they're yours.
This connects to something we think about a lot: 42% of consumers say they'd pay more for products made from upcycled materials, and we think part of that is the uniqueness factor. A mass-produced hat band is the same as the one on the shelf next to it. An upcycled band has its own history.
It also connects to our broader philosophy. Every hat we make is built around the person wearing it. We help you choose the style that works for your face shape, guide you through the crown and brim choices, and then let you design the finishing details yourself. The upcycled bands are part of that. They're the finishing layer where your hat stops looking like anyone else's.
That dynamic works just as well at off-site hat bar events as it does in our studio. When a room full of people all have access to the same upcycled material selection, everyone still walks out with something completely different.
Does Upcycled Mean Lower Quality
Not at all! Upcycled refers to the origin of the material, not its quality. The scrap leather we use comes from the same suppliers producing leather goods for other purposes. The silk offcuts we source are the same quality as the silk they came from. The origin doesn't change the material itself.
The quality of a Gem Hat comes from how it's made. Our team consists of trained hatters, not just designers. They shape and steam your hat, trim the brim, and work with you to get every detail right. That craftsmanship is what makes the hat last, and it's what makes it feel like yours.
We'd also point out that buying new materials doesn't guarantee quality. Some of the cheapest, flimsiest hat accessories on the market are made from brand-new materials. What matters is the material itself, and how it's handled.
If you're curious about the quality of our base hat materials, those are sourced separately from family artisans in Mexico, a relationship Caroline built during her time in Mexico City. You can learn more about that on our story page. The upcycled elements are the bands, silks, feathers, and trims. They're the creative layer on top of a well-made foundation.
And if you want to bring your own material? Go for it! We've incorporated lace from wedding dresses, silk from a grandmother's scarf, and vintage pins that had been sitting in a jewelry box for decades.
Ready to Make Your Own Upcycled Piece?
Upcycled materials at Gem Hats aren't a marketing angle. They're how we've worked since Caroline made her first hats in Mexico City, and they're why the band on your hat is something nobody else has.
When you pick up your finished hat, the leather on the band came from somewhere real. The silk had a life before it was yours. That's what makes a Gem Hat more than an accessory. It's a piece that carries its own history alongside yours.
If you'd like to experience it yourself, book a custom hat appointment at our LoHi studio. We'll walk you through the whole process and help you build something worth wearing for years.
Frequently Asked Questions
What does upcycled mean in fashion?
Upcycled means taking an existing material and transforming it into something beautiful without breaking it down first. In fashion, this typically involves using leftover, surplus, or discarded textiles to create new clothing or accessories. At Gem Hats, upcycling means sourcing scrap leather and surplus silk to make hat bands that would otherwise end up in a landfill.
Are upcycled materials lower quality than new materials?
Nope! Upcycled refers to the origin of a material, not its quality. At Gem Hats, our leather bands come from scrap pieces sourced from the same suppliers producing quality leather goods. The silk we use is surplus from a trusted textile partner. The material itself hasn't changed.
Why do upcycled materials make my hat one of a kind?
Because no two scraps of leather or silk are identical. Each piece has its own grain, color, and texture. When you choose a band at Gem Hats, you're choosing something that exists once. Nobody else will come in and pick the same piece. That uniqueness is one of the main reasons we source this way.
Does Gem Hats use upcycled materials on every hat?
Our upcycled materials are used for the design elements: hat bands, silks, and trims. The base hats (wool felt, suede, and palm straw) are sourced separately from family artisans in Mexico. When you visit our custom hat bar, you'll choose your bands and accessories from a selection made almost entirely from upcycled and repurposed materials.
How does buying a hat from Gem Hats help reduce textile waste?
Every piece of upcycled leather or silk we use is material that didn't go to a landfill. The global fashion industry sends around 92 million tons of textiles to landfills every year. We're a small part of a large problem, but sourcing scrap materials instead of ordering new ones means less demand for fresh production and less waste overall.
Why We Use Upcycled Materials on Our Hats
The roots of Gem Hats extend further than our launch in 2021. And those roots are still impacting our approach to sustainable hat making today.
When Caroline was living in Mexico City, she fell in love with the street markets. Bolts of fabric that nobody wanted. Scraps of silk left over from other projects. Leather pieces trimmed off and tossed aside.
She didn't see those as scraps with no more life. She saw them as gems, pieces that could still be used in the beautiful art of hat making. While learning the craft from locals, she started imagining ways to use those leftovers for a real purpose.
When she moved to Denver and launched Gem Hats, that instinct came with her. Using upcycled materials wasn't a sustainability strategy she developed later. It was baked into the idea from the very beginning. It's how the whole thing started.
Today, when you sit down at our custom hat bar, the bands and trims you choose from are made from those same kinds of materials: scrap leather sourced locally, silk reclaimed from a trusted textile supplier, and other repurposed finds that give your hat a story before you've even started designing it.
Key Takeaways
At Gem Hats, more than 80% of our design materials are upcycled or repurposed. We source scrap leather from local Denver suppliers and reclaimed silk from trusted partners, materials that would otherwise end up in a landfill. The result is a hat band that no one else in the world has. Here's the story behind why we made that choice from day one, and why it matters for the hat you walk out wearing.
Table of Contents
What Are Upcycled Materials?
Upcycled means taking an existing material and giving it a higher, better use than it had before, without breaking it down first. It's different from recycling. Recycling typically involves breaking a material apart and reprocessing it into something new. Upcycling skips that step and transforms what already exists into something meaningful.
In fashion, this usually means turning leftover or discarded textiles into new garments or accessories. For us, it means taking scrap leather and offcuts of silk that would otherwise be thrown away, and turning them into hat bands that become the most personal part of your hat.
The upcycled fashion market is growing fast, currently valued at nearly $9 billion globally and projected to nearly double by 2032. Consumers are catching on to what makers have known for years: materials with a previous life often have more character than anything new.
One thing upcycled doesn't mean is low-quality or haphazard. We're not grabbing random scraps and hoping for the best. Every material we work with is sourced intentionally, chosen for texture, durability, and how it will look and wear on a hat.
The Fashion Industry's Waste Problem Is Real
The global fashion industry produces around 92 million tons of textile waste every year. That's roughly a garbage truck full of clothing and fabric hitting a landfill every single second.
In the United States, about 85% of all textiles end up in landfills annually. Less than 15% are recycled. The rest sit there for decades, or longer, since synthetic fibers can take hundreds of years to break down.
We're not a fashion brand that produces at scale. But we do believe that the choices small businesses make add up. When we source scrap leather instead of buying new, that leather doesn't go into the trash. When we use offcut silk instead of ordering fresh yardage, we're not adding to the demand for new production. It's a small act in a big problem, but it's a genuine one.
Upcycling reduces the environmental footprint of fashion by keeping textiles out of landfills and cutting demand for raw materials. For us, it also just makes sense creatively. The best materials we've ever worked with came from somewhere unexpected.
Where Our Upcycled Leather and Silk Actually Come From
Our upcycled hat band materials come from two main sources: local leather suppliers here in Denver and a trusted silk supplier we've worked with for years.
The leather comes from scrap and offcut pieces, the leftover material from other leather goods production. Instead of going to waste, those pieces come to us and get cut into hat bands. Because every scrap is different in texture, grain, and tone, every leather band we make is slightly different from the last.
The silk works the same way. Our supplier provides us with offcut and surplus silk that would otherwise be discarded. We sort through it, choose pieces that work for hat bands, and incorporate them into the selection you'll browse when you come in for your appointment.
If you want to see exactly how these materials get worked into a finished hat, our post on the cowboy hat shaping process walks through the whole thing from material selection to the final band and branding.
How Upcycled Materials Make Your Hat Truly One of a Kind
Because no two scraps of leather or silk are identical, no two Gem Hats bands are the same. That's not a side effect of using upcycled materials, it's the whole point.
When you choose a hat band from our selection, you're choosing a piece of material that exists once. The grain pattern, the color variation, the texture — those are specific to that piece of leather or silk, and now they're yours.
This connects to something we think about a lot: 42% of consumers say they'd pay more for products made from upcycled materials, and we think part of that is the uniqueness factor. A mass-produced hat band is the same as the one on the shelf next to it. An upcycled band has its own history.
It also connects to our broader philosophy. Every hat we make is built around the person wearing it. We help you choose the style that works for your face shape, guide you through the crown and brim choices, and then let you design the finishing details yourself. The upcycled bands are part of that. They're the finishing layer where your hat stops looking like anyone else's.
That dynamic works just as well at off-site hat bar events as it does in our studio. When a room full of people all have access to the same upcycled material selection, everyone still walks out with something completely different.
Does Upcycled Mean Lower Quality
Not at all! Upcycled refers to the origin of the material, not its quality. The scrap leather we use comes from the same suppliers producing leather goods for other purposes. The silk offcuts we source are the same quality as the silk they came from. The origin doesn't change the material itself.
The quality of a Gem Hat comes from how it's made. Our team consists of trained hatters, not just designers. They shape and steam your hat, trim the brim, and work with you to get every detail right. That craftsmanship is what makes the hat last, and it's what makes it feel like yours.
We'd also point out that buying new materials doesn't guarantee quality. Some of the cheapest, flimsiest hat accessories on the market are made from brand-new materials. What matters is the material itself, and how it's handled.
If you're curious about the quality of our base hat materials, those are sourced separately from family artisans in Mexico, a relationship Caroline built during her time in Mexico City. You can learn more about that on our story page. The upcycled elements are the bands, silks, feathers, and trims. They're the creative layer on top of a well-made foundation.
And if you want to bring your own material? Go for it! We've incorporated lace from wedding dresses, silk from a grandmother's scarf, and vintage pins that had been sitting in a jewelry box for decades.
Ready to Make Your Own Upcycled Piece?
Upcycled materials at Gem Hats aren't a marketing angle. They're how we've worked since Caroline made her first hats in Mexico City, and they're why the band on your hat is something nobody else has.
When you pick up your finished hat, the leather on the band came from somewhere real. The silk had a life before it was yours. That's what makes a Gem Hat more than an accessory. It's a piece that carries its own history alongside yours.
If you'd like to experience it yourself, book a custom hat appointment at our LoHi studio. We'll walk you through the whole process and help you build something worth wearing for years.
Frequently Asked Questions
What does upcycled mean in fashion?
Upcycled means taking an existing material and transforming it into something beautiful without breaking it down first. In fashion, this typically involves using leftover, surplus, or discarded textiles to create new clothing or accessories. At Gem Hats, upcycling means sourcing scrap leather and surplus silk to make hat bands that would otherwise end up in a landfill.
Are upcycled materials lower quality than new materials?
Nope! Upcycled refers to the origin of a material, not its quality. At Gem Hats, our leather bands come from scrap pieces sourced from the same suppliers producing quality leather goods. The silk we use is surplus from a trusted textile partner. The material itself hasn't changed.
Why do upcycled materials make my hat one of a kind?
Because no two scraps of leather or silk are identical. Each piece has its own grain, color, and texture. When you choose a band at Gem Hats, you're choosing something that exists once. Nobody else will come in and pick the same piece. That uniqueness is one of the main reasons we source this way.
Does Gem Hats use upcycled materials on every hat?
Our upcycled materials are used for the design elements: hat bands, silks, and trims. The base hats (wool felt, suede, and palm straw) are sourced separately from family artisans in Mexico. When you visit our custom hat bar, you'll choose your bands and accessories from a selection made almost entirely from upcycled and repurposed materials.
How does buying a hat from Gem Hats help reduce textile waste?
Every piece of upcycled leather or silk we use is material that didn't go to a landfill. The global fashion industry sends around 92 million tons of textiles to landfills every year. We're a small part of a large problem, but sourcing scrap materials instead of ordering new ones means less demand for fresh production and less waste overall.