Print for the felt
How to 3D print a hat block that is ready for the bench.
The measurements and STL are only the first half. A usable block depends on correct size, an honest slicer check, and print settings chosen for the material and work.
Open the free workshop- 01
Choose the finished size and oval
Use the size you intend the finished hat to be. Select round, standard oval, or long oval from the head shape you are trying to fit.
- 02
Generate the crown block STL
Set the crown height and profile in Blocksmith Works, then export the full-size STL. The generator produces the geometry; it does not choose your material or slicer settings.
- 03
Open the STL at 100% scale
Import it into your slicer without resizing. Confirm the displayed dimensions match what you selected before committing material and print time.
- 04
Set up for a smooth working surface
Use adequate walls and infill for the loads you expect. For working blocks, Blocksmith recommends PET-CF as a starting point when your printer and manufacturer settings support it. Random seam placement, adaptive layers, and fuzzy skin off help avoid a raised line or rough surface where the felt will contact the block.
- 05
Print and check the fit
Print the recommended fit check first when you are using a new printer or filament. Then inspect the full block, its bottom holes, and the stand before using it with felt, steam, or pressure.
Keep the first print simple
For a first full-size block, resist the urge to change many variables at once. Confirm the size and oval first. Then refine surface finish, print orientation, walls, infill, and material based on the result at your bench. Measured feedback is exactly what helps Blocksmith Works improve.
Need help choosing the starting geometry? Read hat block sizes and ovals, or learn what the generator includes on the free printable hat blocks page.