I was just thinking about what size 3D printer would be needed to print out a flange. My hat size is 57cm and I prefer a brim on a fedora to be between 2 5/8 and 2 3/4.
I have no idea. I am a hat maker and was joking with the flange maker that we are both artisans using techniques/technology that are over a century apart. He is an engineer and works for a company that makes 3D printers. He is such a geek that 3D printing is what he does in his spare time as well.
Well, he's obliged to print whatever I want.... considering the circumstances, But something like a hat block or flange would take a full roll of filament even if they were hollow. If hollow, the requred thickness would have to be sorted out.
A fellow hatter in my city has branched out into making blocks & flanges. He is a former cabinet maker and has access to a CNC machine. His blocks/flanges are magnificent in a hardwood but pricey. My 3D print guy works for a company that manufactures 3D printers, it is his work and his passionate hobby. I plan to pick up 2 or 3 sets of flanges to fill in the holes. I know nothing about the business but this guy does (he is an engineer). He is willing and he makes money even with his low prices. Randall Alan (RA Hat Blocks) out of NY city has been selling 3D printed hat making tools for a number of years and must be making money as he is still there. There are a number of other newer sellers on ETSY in the 3D print business. Some classic wooden makers are now offering 3D print items as a lower priced alternative to the wood.
The one on the top I coated with a Varathane Diamond coat as I added an extension to the bottom of the block.
John Lofgren Monkey Boots Shinki Horsebuttt - $1,136 The classic monkey boot silhouette in an incredibly rich Shinki russet horse leather. 
Grant Stone Diesel Boot Dark Olive Chromexcel - $395 Goodyear welted, Horween Chromexcel, classic good looks. 
Schott 568 Vandals Jacket - $1,250 The classic Perfecto motorcycle jacket, in a very special limited-edition Schott double rider style. may be Penofin
Nice.
That looks like a nice one
I started over a year ago. Purchased some blocks from several companies including Hat Blocks Australia (http://www.hatblocksaustralia.com.au/open-crowns), currently my favorite place to order from. Nice people and very helpful. The blocks are (IMO) the best, although I have not purchased from Guy Morse-Brown (https://www.hatblocks.co.uk/), which look really nice. Other than that, I keep an eye on ebay to see what comes up.
I use Super Blonde shellac flacks that I purchased from a store on Etsy and 95% denatured alcohol that I buy on Amazon, I desolve the flakes in about 16 ounces of the alcohol then apply it with a paint brush, you could also put it in a spray bottle and spray the brim, however with spray, wear a good mask and you will get it on the crown also, so I suggest using a brush, dip the brush in the mixture and apply in lite coats, let it dry between coats until you get the stiffeness that you want. If you get it too stiff, you can always iron the brim with a good steam iron a couple of times. Another way to stiffen up the brim would be to spritz the hat with rubbing alcohol then ise a Bic Lighter, that will burn off any lose fibers and also stiffen the hat. I have also just sprayed the hat with denatured alcohol completely and let it dry, the felts stiffen up a lot and then I use a steam iron to soften them up if they are to stiff. I am sure that there has to be another way to stiffen up the brims or even clear up soft places in the brim.