Create your own stylish, 3D-printed floppy beach hat with this flexible, multi-part design. Printed with a unique infill-only technique (no top or bottom layers), this hat achieves a beautiful, open-weave, lace-like appearance. The flexible TPU material makes it comfortable to wear and easy to pack. The design is broken into multiple pieces—a top, a four-piece band, and a four-piece brim—allowing for easier printing and seamless assembly using a 3D pen.

Assembly Instructions Print All Pieces: Print all nine hat pieces—the top, four band pieces, and four brim pieces—using a flexible material like TPU. Ensure your slicer settings are configured for no top or bottom layers to achieve the desired lace look. This is already done in the Bambu file included.

Assemble the Band: Take the four band pieces and align them end to end to form a complete circle. Using a 3D pen loaded with TPU filament, carefully weld the seams together from the inside of the band. Assemble the Brim in the same manner as the band.

Attach the Top: Place the hat top piece onto the assembled band. Align the edges and use the 3D pen to fuse the top to the band, working your way around the entire circumference.

Connect the Brim: Use the 3D pen to attach the entire brim to the base of the hat band making sure to line up the seams of the band if that's the look you prefer.

Work quickly since the TPU cools quickly and strings.