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 a client that I block his hats on a 63cm long oval block. Just buy a flange that suits the head size with a 2 5/8" brim, but you would have to specify the degree of brim cupping. How steep do you want the cupping? If you have a flange with a gradual slope that is 2 7/8" wide you could use it but you would end up with a very gentle slope on the cupping.