How to make a poncho (costume)

1. Materials & tools

Materials (For the adult size)

• Main fabric (fleece, felt or light blanket fabric) — about (length × 2 + 20 cm) square
• Bias tape for the neckline (or self-fabric)
• Sewing thread

Tools

• Sewing machine (or needle and thread)
• Fabric marker or pencil
• Ruler and scissors
• Iron
• Pins or clips

2. Make the pattern (auto-generated in Katagami)

With the Katagami pattern tool, you just enter the finished size and it drafts a seam-allowance-included pattern, tiled to print at actual size on Letter or A4.

1. Open the tool
   Open the pattern tool and choose “Accessories” → “Poncho (costume)” from the tabs at the top.
2. Enter the size
   Enter the body width (shoulder), length (neck to point), neckline width and front neckline depth. Presets for child, adult and large.
3. Set the seam allowance
   Use the slider at the bottom (beginners: 1.0–1.5 cm / about 3/8–5/8 in).
4. Print
   Press “Print (actual size)”, then in the print dialog set Scale = 100% and turn “Fit to page” OFF. Check the 50 mm calibration box on the first guide sheet with a ruler.

3. Cutting the fabric

1. Decide the measurements
   Set the shoulder width and the length (neck to point). A longer length makes the four points drape more.
2. Cut
   Cut the front and back each on the fold, one piece each. The front neckline is deeper, the back shallower (per the pattern).

4. Sewing

4-1. Sew the shoulders

1. Right sides together, sew each shoulder line on the left and right.
2. The neck opening forms naturally for the head to pass through.

4-2. Finish the neckline

1. Bind the neckline with bias tape, or double-fold and topstitch.
2. Try it on; if the neck is tight, widen it a little.

4-3. Finish the hem

1. Double-fold the hem all around, including the four points (felt can be left raw).
2. Snip the hem into fringe, or add a separate fringe trim.

✏️ If the neckline is smaller than the head it will not go on. Check that the head passes through with paper or a quick baste before sewing; a slightly deeper front opening helps.

5. Tips & variations

• Change the character: stars or purple for a wizard, primary colors for a superhero, pastels for a fairy.
• Fringe hem: snipping the hem of felt or fleece makes an easy fringed poncho.
• Add a hood: a hood at the neckline makes a more convincing wizard robe.