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I have been always fascinated by embellishing and decorating objects as you can tell from all of my work. When you watch someone create a custom cowboy hat it is truly fascinating, from the steaming, molding and burning to the embellishing with hat bands, branding, jewelry and objects. I wanted to create my own version of the cowboy hat with embroidery and I wanted to make it a work of art while keeping all of the options of a custom cowboy hat.

Imagine designing your own version of the cowboy hat, complete with intricate embroidery and the ability to customize every detail. Our Aspen Cowboy Hat offers the perfect canvas for your creativity to shine.


With three sizes available – 40”x40”, 26”x26”, and 12”x12” – there’s the perfect fit for everyone.

Choose Your Background

The first step is designing the background. We take up-cycled luxury packaging and transform it into strips that are then collaged and embroidered. For added depth and detail, western icons are also embroidered onto the background. Alternatively, you can opt for our custom album background, created using up-cycled album sleeves.

Choose Your Color

Next comes the embroidery. To achieve a truly dimensional look, the hat is meticulously embroidered using over 20 different colors of thread and over 300,000 stitches. The hat is embroidered in multiple pieces, which are later collaged together to create the final masterpiece. You can choose the custom color of your cowboy hat. 

The Hatband

The hat band, made from five luxurious silk scarves, adds a touch of elegance. Each scarf is embroidered and appliquéd to form a unique and eye-catching hat band. You can choose the color story for the hat band. 

Embroidered Details

To further personalize your Aspen Cowboy Hat, we offer additional embellishments. You can customize the brim with a saying, add a playing card, feathers or personalize the crown. 


Each of the embroidered embellishments are embroidered directly onto the hat in your color of choice. You can combine multiple designs to tell your story. 

Aspen series

Aspen 40"x40" - Stephen Wilson Studio
Aspen 40"x40" - Stephen Wilson Studio

Aspen 40"x40"


Unit price

Aspen 26"x26" - Stephen Wilson Studio
Aspen 26"x26" - Stephen Wilson Studio

Aspen 26"x26"


Unit price

Aspen 12"x12" - Stephen Wilson Studio
Aspen 12"x12" - Stephen Wilson Studio

Aspen 12"x12"


Unit price

The Aspen Cowboy Hat is truly a masterpiece that you can customize to your heart's content.

Ready to design your own custom hat? Speak to one of our sales representatives today to get started.

Please note that the 12”x12” Aspen hat has limited customization options due to size restrictions.

Don't miss out on this opportunity to express your individuality and own a one-of-a-kind cowboy hat.