Navigating the turbulence of creating a sustainable, reusable, personalised theatre hat range has not been an easy task. Although embroidered reusable theatre hats were a huge step in the right direction, we decided to investigate and innovate a new product that was even more sustainable, less complex to order, enabled commercial laundering, was scalable onto NHS Frameworks, and more financially viable for hospitals to implement.

Our Journey

Our journey of discovery has certainly been comparable to being on an aeroplane with jet streams and changes in air velocities — exhilarating highs of success integrated with a multitude of lows and setbacks, leading us to our now readily available product range.

One of the most rewarding aspects was the opportunity to bring our vision to life. Our exploration of numerous fixation techniques and prototypes has fused two tried and tested ideas together: fabric theatre hats and name badges. We looked back to the 1920s, when theatre hats were first worn in hospital theatres throughout the world, to discover how that concept could be transformed and made relevant today.

Clear Window Hats — A Learning Curve

Initially, clear window hats appeared to be the golden ticket. However, feedback was negative from the outset due to the integrated plastic — something healthcare is actively trying to move away from. Written cards and paper inserts looked shabby, needed replacing daily due to laundering, and created 'dog ears' on corners. Printed name badges to slot into the window were uncomfortable on the forehead and caused friction.

The nail in the coffin for the clear window design came from infection control and laundering research. The window could trap moisture inside — an optimum environment for bacterial growth and mildew. Over time, the clear window would also lose clarity with each wash. Commercial laundering partners confirmed that the rigorous wringing process used to remove excess water caused cracks in the window, defeating the entire purpose of the product.

Progress Through Failure

As Einstein said: "Failure in success is progress." Ruling out the clear window approach led us to a new path — a fixation method that eventually passed all tests and ticked all boxes.

We don't just sell theatre hats. We conduct thorough research to clearly understand the market and produce robust test results that ensure our products are of the very best design quality — giving confidence to customers considering making the switch.

All our test results are available to read on our website. If you'd like to find out more about our badge hat range, please get in touch.