Does this hat breathe at all, does the head get hot?

I don’t think it makes your head hot… very light and comfortable…

A lot of reviews mention different sizes but it just says one size in the listing, has something changed, if so what size is it now?

There are different sizes. The hat fits snug for its size (probably to help keep it on your head) It can get uncomfortable if you’re one of those between size people.

how many inches are the brim of this hat?

Just about 3”. Great sun protection all around, I use mine in the water all the time.

What is the material of the shell?

Perfect 🙌🏻 Sorry not sure on this answer. But if you need a good water hat or hat that stays on great THIS IS THE BEST CHOICE

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