How to make a santa hat

1. Materials & tools

Materials (For the adult size (57 cm head))

• Main fabric (red fleece or felt) — about 70 × 60 cm
• White boa (for the brim and pompom) — about (head + 5 cm) × 15 cm
• Polyester stuffing (for the pompom) — a little
• 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” → “Santa hat” from the tabs at the top.
2. Enter the size
   Enter the head circumference, cone length and white brim width. Presets for child, adult and long & floppy. Measure the head and enter the real number.
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. Measure the head
   Measure and enter the real head circumference; add 1–2 cm for a loose fit. For a child, measure their own head.
2. Cut
   Cut one cone hat, one white brim band and one circle for the pompom. Felt can be left with raw edges.

4. Sewing

4-1. Roll the hat into a cone

1. Sew the straight center edges right sides together to form the cone.
2. Press the seam open or to one side.

4-2. Attach the white brim

1. Fold the white boa band, sew the ends into a ring.
2. Match the ring to the hat's opening right sides together and sew all the way around. Fold the brim to the outside.

4-3. Make and attach the pompom

1. Gather the edge of the circle, stuff it and round it into a pompom.
2. Sew it firmly to the tip of the cone.

✏️ In felt, the edges do not fray, so you can attach the brim as a single (unfolded) layer, or just stack circles for the pompom — even simpler.

5. Tips & variations

• Floppy look: make the point longer and let the tip flop forward for a cute, plush Santa hat.
• Change the color: green for an elf, white and pale blue for a snow fairy; sequins on the brim look festive.
• For pets: make it small and add a chin strap for a pet Santa hat.