DIY Santa Hat with Sewing Pattern in 4 sizes [VIDEO]
Get into the festive spirit with this quick and cheerful sewing project! In this tutorial, you’ll learn how to sew your very own classic Santa hat using our printable pattern with 4 different sizes. With just a bit of red satin velvet, some soft white faux fur, and a few basic sewing supplies, you can create a cozy, professional-looking hat that’s perfect for holiday parties, photos, or gifting. Whether you’re a beginner or an experienced sewist, this simple project is a fun and satisfying way to add a handmade touch to your Christmas celebrations.
Below you will find my step by step written tutorial how to make a santa hat with VIDEO instructions for all the visual learners.
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Table of Contents
- 1 How to make a Santa Hat
- 2 Supplies and tools
- 3 How to Sew a Santa Hat
- 3.1 DIY Santa Hat VIDEO TUTORIAL
- 3.2 INSTRUCTIONS:
- 3.3 STEP 1:
- 3.4 STEP 2:
- 3.5 STEP 3:
- 3.6 STEP 4:
- 3.7 STEP 5:
- 3.8 STEP 6:
- 3.9 STEP 7:
- 3.10 STEP 8:
- 3.11 STEP 9:
- 3.12 STEP 10: Divide the band in quorters
- 3.13 STEP 11: Divide the hat in quorters
- 3.14 STEP 12:
- 3.15 STEP 13:
- 3.16 STEP 14:
- 3.17 STEP 15:
- 3.18 STEP 16:
- 3.19 STEP 17:
- 3.20 STEP 18:
- 3.21 STEP 19:
- 3.22 STEP 20:
- 3.23 STEP 21:
- 3.24 STEP 22:
How to make a Santa Hat
Supplies and tools
- fabric – red stretchy velvet or knit fabric for the hat. Felt or plush will also work but may be a bit on the smaller side
- fabric – white faux fur or white felt for the band and the pom pom
- a handful of polyester stuffing or cotton
- matching thread
- scissors (or rotary cutter and a cutting mat)
- ruler or measuring tape
- iron and ironing board
- sewing clips or pins
DOWNLOAD: santa hat sewing pattern in 4 sizes (L, M, S, XS) [Free pdf file]
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How to Sew a Santa Hat
Watch the diy santa hat video first and then follow the written step by step instructions below.
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DIY Santa Hat VIDEO TUTORIAL
INSTRUCTIONS:
STEP 1:
Download the pattern, and tape it together. You will have three pages on row 1 (A1, A2 and A3) and only one page on row 2 (B1) for a total of 4 pages. Tape page A1 to page B1 and page A2 to page A3. Decide which size you want to make and trim the excess paper. Put the santa hat pattern aside.
STEP 2:
Take your red fabric for the body of the hat and fold it in half with the pretty sides facing each other. Place the pattern on the fold and cut the fabric. You will need to cut 2 red fabric pieces.
STEP 3:
Place both fabrics on top of each other, right sides facing and pin the sides.
STEP 4:
Stitch the sides using a stretch or a zig zag stitch and 1cm (3/8″) seam allowance. Do not stitch the bottom or the very top.
STEP 5:
If you are using a white felt, fold it in half and place the pattern on the fold then cut it out.
If you are using faux fur, the chances are it would be too thick to cut through 2 layers at once so don’t fold the fabric in half. Place the white faux fur on the top of your workplace and place the band pattern on top making sure you have enough fabric on the right to cut out the whole band. Cut the top, bottom and the left side. Flip the pattern along the FOLD mark and cut out the top, bottom and the right side. The video explains this step well, so watch it if you need to.
STEP 6:
Fold the band in half lengthwise with the right sides facing each other and pin the short sides together.
STEP 7:
Stitch the band using 1cm (3/8″) seam allowance.
STEP 8:
Trim down the seam allowance of the hat to about 6mm (1/4″)
STEP 9:
Press open the seam allowance of the band and fold it in half with the wrong sides together so long raw edges meet.
STEP 10: Divide the band in quorters
Match the seams and pin in place. Find the opposite side and pin in place. To divide the band in quarters, match both pins in the middle to find the two opposite quarter points and pin each one.
STEP 11: Divide the hat in quorters
Place a pin in each of the side seams. Match the pins to find the opposite quorter points and place a pin in each point.
STEP 12:
Insert the hat with the wrong side outermost inside the band. Align the raw edge of the hat with the raw edge of the band and match the pins. Make sure the seam of the band is not pinned to the side seam of the hat – it should be at the back. Pin the band to the hat.
STEP 13:
Sew the band to the hat using a 1cm (3/8″) seam allowance.
STEP 14:
To finish the hem either serge it or use a zig zag stitch the hem the edge.
STEP 15:
Turn the hat around and fold the faux fur band up
STEP 16:
The last step is to make the pom pom. Take a piece of white fur and cut out a 13 cm (5″) circle.
STEP 17:
Thread a hand sewing needle with a length of strong thread. Knot the end and sew a running stitch all around the circle.
STEP 18:
Pull the thread to gather the fabric a bit leaving a gap.
STEP 19:
Fill in the pom pom through that gap with a bit of the polyfill stuffing.
STEP 20:
Pull the thread more to close the gap and stitch it close. The pom pom is finished
STEP 21:
Fold in the top of the hat about 1 cm (3/8″) and stitch the pom pom to the top of the hat. Voila! The DIY Santa Claus Hat is ready!
STEP 22:
(OPTIONAL) if your lining keeps showing under the faux fur, run a stiching line around the bottom of the hat (zig zag or a stretch stitch).
That’s it! The santa hat is now finished!
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