Formillion is Formillionaire’s own answer to a problem every hatter runs into sooner or later: head sizes vary, but a solid hat block only ever covers one of them. Instead of printing (and storing, and shipping) a separate block for every centimeter of head circumference, the Formillion system is built around one core plate that expands across a wide 54-64cm range using a small set of interlocking, 3D-printed parts.
What the System Actually Is
Formillion isn’t a single product — it’s three parts designed to work together as one adjustable sizing system:
- Formillion Plate — the base component the rest of the system builds on, a precisely dimensioned starting plate rather than a fixed-size block.
- Formillion Expansion Kit (54-64cm) — a set of interlocking spacer/expansion pieces that step the base plate up through the full size range in defined, repeatable increments, instead of needing a new print for every centimeter.
- Formillion Hat Stretcher & Sizing Tool — a companion tool for fine-tuning and verifying the final size once the plate and expansion pieces are assembled, so the finished dimension matches the target head measurement rather than just “close enough.”
Why One System Instead of a Block Per Size
A milliner or small hat studio serving walk-in customers can’t always predict which size will be needed next. Keeping a shelf of ten-plus wooden blocks in half-centimeter steps is expensive and slow to expand. Formillion inverts that: print the base plate once, then print (or reuse, depending on the specific size gap) the expansion pieces needed to reach the size in front of you. The result is one flexible system that covers a whole customer base instead of a fixed, one-size-at-a-time inventory.
Who It’s For
The Formillion system is aimed at exactly the situation the standard single-size blocks in the rest of the catalog don’t solve well: a working hatter who needs to move between sizes often, a small studio building out a size range gradually rather than all at once, or anyone who would rather own one adjustable system than a growing shelf of individual blocks.
Getting Started
Browse the individual Formillion components in the full catalog, or pair the system with a custom-sized brim using the brim plate generator once your crown size is set.
