Behind the Design: Making the “Fueled by Welds & Espresso” Hat
Designing a hat for Bay & Stew started with a simple goal: create something playful, wearable, and full of personality. The process might seem straightforward, but every step—from brainstorming phrases to picking materials—was about refining the details until it felt just right.
Exploring Phrases
The first step was thinking about the words.
The team explored a few different ideas:
- “Jewelry & Espresso”
- “Welded & Wild”
- “Permanent Mood”
- “Fueled by Welds & Espresso”
The final choice landed on “Fueled by Welds & Espresso.” It struck the right balance of playful, bold, and a little cheeky—a phrase that immediately feels like Bay & Stew.
Sketching the Design
Once the phrase was set, sketches began. A coffee cup felt like a natural starting point, but the design evolved with little touches that made it unique: a welder’s tool and a coffee bean replacing the “O” in espresso. Several variations were created, some worked, some didn’t—but every sketch helped guide the final version.
Choosing Colors & Materials
Next came the hat itself. After experimenting with different colors and materials, we went with brown corduroy and dark brown embroidery. The goal was simple: create a design that resonates with Bay & Stew customers, feels approachable, versatile, and serves as a small way to give back to our loyal community.
Embroidery & Production
With the design and materials finalized, the hat moved into production. Once embroidered, the final design came to life, with details like the coffee bean and welder’s tool adding texture and character. When the hats were delivered and shared with the team, all the design choices—from layout to thread color—finally felt tangible.
Reflections on the Process
This hat came together through careful exploration. Testing ideas, refining sketches, selecting materials, and coordinating with the factory for quality and proofs all contributed to a playful, thoughtful design that’s unmistakably Bay & Stew.