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Jan Davidson had two days to make Oprah happy.

Her production company was shooting a TV movie and the producer desperately needed a woman's wedding hat. Davidson got the job with no time to spare. The hat had to be on the set by Monday morning, and it was already Friday. But this was not just any old hat. Some 1,000 small silk flowers were to garnish it, and Davidson had to stitch each one not with a sewing machine, but by hand.

"I practically spent 48 hours with my eyes open and my hands practically bloody making this hat," says Davidson. She is a milliner in North Carolina. "It was a very, very intricately made hat. But it was well worth it, and it was well received."

It was also a major career highlight for Davidson. She credits her two grandmothers for starting her career in millinery, the art and craft of making hats for women.

Although they were not milliners, they gave Davidson a love for working with her hands. "And I have always loved design, color, style and form -- all those things. And I have dabbled in so many different things, like silk ribbing, embroidery and crocheting."

And yes, Davidson collected hats as she was growing up.

Those interests came together in 1995 when she and her husband moved to Australia. Stays in Brisbane and Melbourne exposed her to the complex and colorful world of millinery. She soon enrolled at the Melbourne School of Millinery, one of the few schools to offer formal education in that field.

Milliners work with their hands to design and create unique hats for women.
Courtesy of: Wayne Wichern

"It pulled all those things together," she says. "So for me, [millinery] is not only something I do to make money, but it is also a very strong creative outlet. The creative part is just as much a motivator as making money from sewing. It is working with my hands and creating something."

And as any artist will tell you, creating something new is an often frustrating and exhausting struggle.

Davidson says she usually has a firm idea of how she wants a hat to look. "But it is amazing how many times a hat will take on its own life. It won't be what I want it to be. It is only going to be what it wants to be."

She still recalls the agony she experienced over a hat she made for a local store. "This hat took on three different lives," she says. "We fought the entire time. It went to the shop three different times as three different hats. I was never pleased with it."

Davidson eventually just went along to where creativity took her, and the hat sold the day after she had brought it to the store.

This artistic struggle is part of a greater struggle to survive in a field that has existed on the fringes of the fashion world. That has not always been the case.

For the first half of the 20th century, everybody wore hats and dressed up for most social occasions, including baseball games. But the economic boom of the 1950s gave the public more time and money for recreation and leisure. Soon Hawaiian shirts and baseball caps began to replace dress shirts and hats.

This dressing-down reached a climax in the 1960s as the social and sexual revolutionaries branded hats symbols of the oppressive establishment. "The millinery business was just booming in the 1930s, 1940s and 1950s," says Wayne Wichern. He is a milliner in Seattle. "In the 1960s, it crashed."

It picked up again in the 1980s when stocks and hairdos rose to new and tacky heights. It has continued to grow since, but it will never be what it was because North American society continues to become more casual in dress and manners.

Wichern says we have become a hugely casual society because our lives have become more complicated.

The logic is simple: the more complicated our lives become, the less time and money we want to spend on clothes and headwear. Instead, we want to dress in a way that does not require a lot of time, effort and money.

This has made it difficult for people like Wichern to make a living, and he has to supplement his income by teaching his craft to others.

Efstathia Xynnis also feels comfortable in her little millinery shop, and she doesn't think her trade is antiquated. "I don't feel out of place," she says. "People still have a need for things that are customized, or more specially made. They don't want ready-to-wear [hats]. It doesn't suit them. It doesn't fit them. They don't like it. They want more."