Behind the Patch: Meet the Makers
Every custom leather patch hat we send out has been touched by real hands, shaped by real stories, and crafted under one roof. We're not a faceless brand or a print-on-demand warehouse. We're a small family-run business with a big heart — doing things the hard way because it’s the right way.
Here’s the crew behind every patch you’ve ever worn.
👨🏭 David McHenry – Founder, Vision Builder, Head Hat Nerd
David started Hat Foundry with nothing but a laser, a cold garage, and a head full of ideas. What began with one oversized, burnt patch has become a full-blown operation that's helped nearly 500 businesses bring their brand to life.
He leads with vision, grit, and an eye for detail. Whether it's product testing, tool development, or launching new systems to help other hat makers, David is the hands and heart behind the mission: build better hats, build a better industry, and keep it all in-house.
👩🔧 Brea McHenry – Production Supervisor & The Calm in the Chaos
Brea came on board in March of 2025 as demand grew and shipping times slipped She is the reason orders are shiping on time, quality stays consistent, and the shop doesn’t fall into creative anarchy. From managing the production floor to keeping materials organized and processes locked in, she runs a tight ship — and keeps us grounded.
If you've ever received an order that looked flawless, flowed smoothly, and somehow still had a personal touch — Brea was behind it.
🧢 Phoenix Jean – Workshop Boss Baby & Vibe Curator
At just 3.75 years old, Phoenix already runs the shop — or at least, she’s convinced she does (and honestly, we’re not arguing).
From calling the shots on music playlists to deciding when it’s snack time, Phoenix sets the tone in the workshop. She brings the energy, keeps us in check, and somehow manages to lighten the mood even during a tight production crunch.
She might not be placing patches (yet), but she’s already a cornerstone of the culture at Hat Foundry. This is her empire — we’re just working in it.
🐾 Chief Barketing Officer (In Memoriam)
Before there was a laser, before there were patches, there was Lucy. She kept our feet warm during late-night engraving sessions and made sure we took breaks when we didn’t want to.
She crossed over the rainbow bridge in early 2025, but we still catch ourselves expecting her to bark at the mailman or beg for just one more treat. Lucy was the original shop dog, and we’re better because of her.
This Is Who We Are.
We don’t outsource. We don’t cut corners. And we don’t take your trust lightly.
When you work with Hat Foundry, you're not just getting a product — you're getting the full weight of a small team who gives a damn. From design to delivery, it’s all personal to us.
Thanks for supporting small. Thanks for getting to know us
