How to sew a santa hat: sizes, steps and fabric

To sew a Santa hat, cut a tall curved cone shape of red fabric, sew the long edge into a point, then add a folded white brim at the bottom and a white pom at the tip. Measure around the head first and pick the size that matches, so the brim sits snug. The Santa and Elf Hats pattern in the Sewzy app is rated beginner and takes about an hour.

TL;DR

• A Santa hat is a cone of red fabric with a white brim and a pom.
• Measure around the head where the hat will sit, then choose the size by that number.
• The Santa and Elf Hats pattern is in the Sewzy app, rated beginner, about 60 minutes.
• It covers four sizes from toddler to adult, and makes both a Santa hat and a pointed elf hat.
• Fleece is the most forgiving fabric because it does not fray and has a little give.

What size Santa hat do I need?

Measure around the head with a tape where a hat sits, just above the ears and eyebrows. Match that number to the size. The Santa and Elf Hats pattern comes in four head sizes:

If a head falls between two sizes, pick the larger one. The folded brim takes up a little room, and a hat that is slightly loose is easy to tack smaller.

What fabric is best for a Santa hat?

• Red: fleece, felt, velvet or crushed velour for the cone. Fleece and felt do not fray, so they are the kindest for a first hat.
• White: fleece or faux fur for the brim and the pom. Faux fur looks the most festive but sheds while you cut it.
• Elf version: green and a bright trim work for a pointed elf hat from the same pattern.

Fabric amounts for every size are in the Sewzy app, so check them before you buy.

How do you sew a Santa hat, step by step?

1. Measure and choose the size. Measure the head and print the matching size at home.
2. Print and tape the pattern. Line up the marks and tape the pages into the full shape.
3. Cut the cone. Cut the hat piece from red fabric on the fold or as two halves.
4. Sew the point. Fold the cone right sides together and sew the long slanted edge from the brim up to the tip. This forms the cone.
5. Make the brim ring. Join the white brim strip into a loop and fold it in half the long way.
6. Sew the brim to the hat. Pin the white loop around the bottom of the red cone, raw edges together, and stitch all the way round.
7. Turn and press. Turn the hat right side out so the brim folds up and the seam hides inside.
8. Add the pom. Make a white pom or use a ready one, and hand sew it firmly to the point.

The full pattern in the app breaks these into clear steps with a brim cuff and the pom, and the same pattern makes the elf version.

How long does it take to sew a Santa hat?

About an hour for a first one, less once you have made a couple. There are only a few seams, so most of the time goes on cutting and on making the pom full and even. If you are sewing a set for the family, cut all the cones at once and sew them in a line, which is faster than finishing one hat before you start the next.

Should I sew a Santa hat by hand or machine?

A machine is quicker and gives a stronger cone seam, but a Santa hat is small enough to sew by hand if you do not own a machine. Use a backstitch for the long cone seam so it holds, and whip the brim on. Felt is the best choice for hand sewing because the edges will not fray. For a no-sew version you can glue a felt hat, though it will not last as long as a stitched one.

How do I make a Santa hat fit better?

If the hat is a little loose, run a line of hand stitches through the inside of the brim and gather it in slightly, or tack a short length of ¼ inch elastic across the back of the brim so it grips. For a toddler who pulls hats off, add a soft chin tie from a strip of the white fabric. Measuring the head before you cut, and rounding up between sizes, avoids most fit problems in the first place.

Is a Santa hat a good beginner project?

Yes. It is all straight and gently curved seams, no zippers or buttons, and fleece hides small wobbles. It is a good match for someone who has finished an easy first project and wants something for the season. Keep a basic sewing kit to hand and you have everything you need.

More Christmas makes

If you are sewing for the season, the Santa hat pairs well with the Cone Christmas Trees and Christmas Ornaments in the Sewzy app for a matching set. For gifts, see the handmade Christmas gifts guide and how to sew a Christmas stocking.

Common mistakes

• Guessing the size. Measure the head first. A hat cut too small will not pull over the ears once the brim is folded.
• A thin, floppy pom. Make the pom full and sew it on with several firm stitches so it does not droop or drop off.
• A hot iron on faux fur. Faux fur and velvet flatten and can scorch. Press the seams lightly from the back with a cloth, or finger press.
• Sewing the brim on flat. Join the white brim into a ring first, then sew it round. Sewing it flat leaves a gap at the back seam.