>>96183815
as the other anon says, you could commission someone to make and print a few hats. I just put this together to show it can at least be done, this one's very rough because it took me 30 minutes total including time to look for a logo I wanted to copy, I'm still pretty amateur, and I made the logo from scratch instead of tracing it like you usually would. Once you get to this stage though you can copy/paste a lot of assets to make different designs quickly, so someone experienced in 3d modelling should be able to make a set of varied hats with varied logos in 2-3 hours, 4-5 tops if they go to town.

Otherwise if you want to work with physical media then I would personally get 6mm styrene rod for the base rim of your hat, then maybe 9mm or 10mm rod for the top rim, and build up the middle bit with some sort of modelling putty that you can then sand to a variety of shapes.