Travel-ready hats solve a real problem: traditional structured hats take up precious luggage space and lose their shape when packed. Conner's packable collection features hats made from flexible materials like organic cotton, waxed cotton, wool felt and recycled polyester that can be folded, rolled, or compressed without permanent creasing. These aren't delicate accessories—they're built for adventure.
The material matters. Soft wool felt flexes and reshapes easily. Organic cotton and canvas can be folded along the crown. Our waxed and oiled cotton styles add water protection, protecting you in unexpected weather while remaining flexible enough to tuck into a backpack side pocket.
Many styles in this collection offer sun protection. Wide brims (3+ inches) provide coverage for face, ears, and neck, areas often missed by sunscreen alone.
Every hat in this collection is handmade or carefully sourced by a family-owned business that's been crafting hats for over 50 years. Bill Conner started making leather hats in Australia in 1970 and has made hats in Byron Bay for over 50 years. His son Will brought that craftsmanship to the U.S. and expanded the line to include sustainable materials found in this collection: organic cotton, recycled polyester made from recycled plastic bottles, and Australian wool. When you see "BC Hats" in the product names, those are Bill's original designs, made in Byron Bay, Australia.
Packable hats are designed to be folded, rolled, or compressed for travel without permanent damage. Crushable hats are made to recover their shape after being compacted. Material matters, but construction matters too: some safari hats are packable, many wool hats are crushable, and some hats are intentionally stiff. For Conner Hats styles, check the product details and care guidance before packing; some styles may need to be reshaped after travel.
For fedoras and outback styles: turn the hat upside down (crown down, brim up) and place it in your luggage with soft items like clothing around it for cushioning. For bucket hats and soft caps: fold gently in half or roll from brim to crown, securing with a soft band. Newsboy and flat caps can be folded flat. Never store hats compressed long-term—crushability is for short-term transport (hours to a few days). When you unpack, let the hat rest on a flat surface. If creases remain, hold it over steam from a kettle or use a handheld steamer, then reshape with your hands.
Yes, if packed correctly, but how well a hat holds its shape depends on the style. Many wool hats are crushable, while some are stiff on purpose. Check the product description for your hat’s material and packing guidance. If it needs reshaping after unpacking, a stretch or steam can help restore its shape.
Many of our hats are UPF rated; check each product page for its rating. Hats without a UPF rating provide shade from the brim, but do not have a UPF rating.
Some are. Our waxed and oiled cotton hats (like the Portland Waxed Cotton Rain Hat and Kentucky Waterproof Oiled Cotton Cap) are water-resistant and designed for wet conditions—rain, fishing, boating. They shed water rather than absorbing it. Organic cotton and canvas hats are not waterproof but can handle light drizzle; they'll dry naturally but shouldn't be soaked. Wool felt hats have natural water resistance to an extent but will lose shape if fully saturated. If you need a hat specifically for rain or water sports, look for the Portland Waxed Cotton Rain Hat or Kentucky Waterproof Oiled Cotton Cap.
Care depends on the material. For organic cotton and canvas hats, spot-clean with a damp cloth and mild detergent, then let them dry naturally; do not fully soak them or machine-dry them. Wipe oilskin and waxed cotton hats clean with a damp cloth, and avoid submerging them because it can strip the protective coating. Brush Australian wool felt hats with a soft brush and spot-clean them; steam can refresh them. Always check the care label inside your specific hat. If you're unsure, contact us for material-specific guidance.
BC Hats were made by Bill Conner in Byron Bay, Australia; these are the original designs from the family business that began in 1969. They're known for Australian outback styles, often made from leather, canvas, and mesh with a focus on durability and ventilation. Conner Hats styles are designed by Will Conner (Bill's son) and manufactured globally with an emphasis on sustainable materials: organic cotton, hemp, recycled plastics, and non-mulesed wool. For purchases from connerhats.com, the Limited Lifetime Guarantee covers workmanship failure (50% off if lost or stolen). When you see "BC Hats" in a product name, it's an Australian-made original.
Yes. Hats purchased from ConnerHats.com are covered by our Limited Lifetime Guarantee. For a workmanship failure within the first 12 months, we’ll replace the same style, size, and color, including shipping. After 12 months, a replacement is available at 40% off, with shipping not included. Material degradation from use is eligible for a 30% off code. If your hat is lost or stolen, you can get 50% off the same hat, with shipping not included. Email photos, your order number, and a description of the issue to customerservice@connerhats.com, and we’ll help you with next steps.
