Looking for a fun and easy holiday sewing project with that quick-finish gratification? These Santa hats pair fuzzy fleece with your favorite cotton prints to make fun, modern, cozy hats for all your festive moments. They are the perfect weeknight / weekend project – they come together super fast – and it’s impossible to make just one!
All our holiday collections would be perfect for these hats. The three shown in this tutorial were all made with Noel, our most recent Christmas collection, in stores now. Get the full tutorial and pattern pieces below!
- Santa Hat Template (download here)
- 5/8 yd main fabric
- 5/8 yard fleece for lining
- Optional: 1/4 yard super fuzzy fleece for band and pom pom (if you don’t get this, the 5/8 yard of fleece for the lining is enough for the band and pom pom as well)
- Cotton+Steel Thread by Sulky
- Hand sewing needle
Note about the fleece: For the band, something with some stretch works the best. Both our fleeces are from the baby blanket section of Joann Fabrics.
ERRATA: On the pattern piece it says to cut 2 of fleece, but it should read cut 1.
Print out the template, being sure that your printer is set to print at 100%. There is a 1″ square you can measure on the printout to check. Cut out the pieces and use the taping diagram to tape together hat.
From main hat fabric, cut one Main Hat template on the fold.
From fleece lining, cut one Main Hat template on the fold. (Be sure to leave room for the band if using same fabric.)
From extra furry fleece, cut Band: 25″ wide by 7.5″ tall, and Pom Pom.
All seam allowances are 5/8″ unless otherwise noted.
Fold main fabric hat in half, right sides together, and pin together straight edges.
Stitch edges together. Trim top point as shown below.
Press seam open.
Repeat process with fleece lining, minus the pressing. To reduce bulk, trim entire seam allowance of fleece lining in half.
Turn main hat right side out. Put lining inside main fabric so that wrong sides of both fabrics are touching.
Line up bottom raw edges, aligning seams and pinning all the way around. Put your stitch length up to 4.0 and sew all the way around the bottom edge at 3/8″.
Fold band fabric in half with right sides together, aligning short ends. Sew short ends together. (TIP: After sewing, fold the band in half and try it on for size. If you’d like it to be snugger, re-sew the seam a little further in from the edge.) Trim seam allowance.
Fold band in half, wrong sides together, lining up the two long raw edges.
Place folded band inside hat with the folded edge of band pointed towards the inside. Line up band and hat seams and pin.
Work all the way around, lining up the raw edges and pinning everything together. If you made your band shorter, you’ll need to stretch it a little to make it fit the hat. That’s ok!
Stitch all the way around the bottom edges at your 5/8″ seam allowance, backstitching at the beginning and end. If you’re using super fuzzy fleece like we are, we recommend putting your stitch length all the way up – the thickness of the fabric will eat up that length and your stitching will look normal. Also, this is a thick seam. You may need to gently pull the fabric through the machine as you sew. Be prepared to (wo)manhandle it.
Sew the same edge at 3/8″ with a zig zag stitch. Again, womanhandle that fabric and show it who’s boss. Then trim the excess just outside the zig zag.
Fold the band up to cover the seam.
On the Pom Pom piece, use a hand sewing needle to sew a large running stitch all the way around about 3/8″ in from the edge, leaving tails long and unknotted. We used green thread so you can see, but you’ll want to use something that matches your fleece.
Gently pull on thread tails to tighten. Stuff pom pom – this is a perfect chance to use up some fabric scraps!
Once stuffed, gently pull the threads to tighten all the way. Tie into a knot, but don’t trim yet. Stitch back and forth across the top of the pom pom until it feels tightly closed.
Tie another knot, then hand stitch the pom pom onto the tip of the hat.
Tie a final knot then bury the thread tails in the pom pom. Put on your new hat and find some cookies to decorate or presents to wrap!
Then make a hat for all your friends!
Be sure to tag your makes with #cottonandsteel on social media so we can see!
Note: This is a one-size-fits-most-adults pattern, but it would be easy to take it in to fit kids! In the instructions above, sew the band first and have the kid try it on for size so you can see how much to take it in. If it’s taken in a ton (say, more than 4 or 5″) you should probably take in the hat seam a bit as well. By sewing the band first you can see if you need to adjust the hat at all before you attach the outside and lining together at the bottom.