Some projects go beyond signage. They become symbols.

Last month, Mello Signs proudly unveiled The Big Hat in Garland, Texas — a 20-foot-wide, 16-foot-tall cowboy hat designed and engineered to capture the spirit of Texas while delivering bold visibility for the city.

From the first sketches to the final illuminated structure, The Big Hat represents what happens when a community’s vision meets craftsmanship, engineering, and artistry.

Big Vision, Bold Execution

The City of Garland wanted more than a sign — they wanted an icon. Something playful, memorable, and unmistakably Texan.

Our team worked hand in hand with city leaders to bring that idea to life. The result: a sculpted fiberglass and steel structure that commands attention day and night, with a presence that’s as bold as the Lone Star State itself.

Engineering a Texas-Sized Statement

Building The Big Hat meant pushing design and engineering to new heights:

• 20 feet wide and 16 feet tall — engineered to withstand Texas weather.
  
• Steel and aluminum framework — precision-built for strength and stability.
  
• Fiberglass and urethane foam finishing — carved and shaped to deliver the perfect curve.
  
• RGBW color-changing faux neon — illuminating the brim and hat band for a show-stopping glow.
  
• Custom City of Garland logo — seamlessly integrated into the illuminated design. 

Every detail was carefully considered, from structural bracing and lift points to hidden electrical pathways that keep the design clean while ensuring long-term performance.

From Workshop to Landmark

Fabricating The Big Hat was a multi-phase process that combined heavy-duty engineering with hand-finished artistry. Our team routed and assembled the primary framing, carved custom foam for the curves, and layered fiberglass for durability.

The final touches — painting, logo installation, and faux neon integration — transformed the structure into something larger than life. At night, the hat glows with shifting color, turning Garland’s newest landmark into an illuminated beacon.

Why It Matters

Landmarks like The Big Hat aren’t just visual features. They’re points of pride. They give communities something to rally around, something that sparks conversation, and something that visitors remember.

For Garland, this project represents more than steel and fiberglass. It’s about celebrating heritage and creating a destination piece that belongs to the city for decades to come.

Building Icons, Not Just Signs

At Mello Signs, we don’t stop at signage. We build experiences, landmarks, and statements that define communities and brands alike. The Big Hat is just one example of how vision, collaboration, and craftsmanship come together to create something unforgettable.

Looking to bring a big idea to life? Explore our custom signage services, browse our portfolio of past projects, or contact us today to start building your landmark