How to make a witch hat

1. Materials & tools

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

• Main fabric (felt, heavy cotton or canvas — something with body) — about 90 cm wide × 70 cm
• Fusible interfacing (heavyweight, optional) — enough for the cone and brim
• Optional: lining fabric (to make the brim double-layered)
• Optional: trims (ribbon, buckle, stars)
• 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” → “Witch hat” from the tabs at the top.
2. Enter the size
   Enter the head circumference, the cone length (peak) and the brim width. Presets for child, adult, and low crown / wide brim. Always 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 the actual head circumference and enter it. Add 1–2 cm for a loose fit. For a child, measuring their own head is the surest way.
2. Trace the pattern
   Trace the printed pattern onto the fabric. Felt does not fray, so a small seam allowance (about 0.7 cm) is fine. Fuse interfacing wherever you want the point to stand.
3. Cut
   Cut one cone crown and two brim halves in the main fabric. For a double-layer brim, cut two more in lining. Fuse interfacing to the cone and the outer brim.

4. Sewing

4-1. Roll the crown into a cone

1. With right sides together, sew the two straight edges of the fan to each other. That forms the cone.
2. Press the seam open or to one side.
3. If you are lining it, sew the lining into a cone the same way.

4-2. Join the brim into a ring

1. Put the two main-fabric brim halves right sides together and sew both straight ends to make a ring (doughnut).
2. Join the two lining halves into a ring the same way.
3. Put the main ring and lining ring right sides together and sew all the way around the outer edge. Turn right side out through the inner hole and press the outer edge.

4-3. Attach the brim to the crown

1. With right sides together, match the base of the cone (the bottom arc) to the inner hole of the brim. The circumferences are equal, so it fits all the way around.
2. Match the center-front notch, then pin all around.
3. Stitch once around the inner edge. Press the seam toward the brim for a clean opening.

4-4. Finish

1. Shape the tip of the point with an awl. With interfacing or felt it will stand on its own.
2. If needed, fold the opening edge (inner brim) under and finish it narrowly.
3. Add a ribbon, buckle or star motif to make it read as a proper witch hat.

✏️ If the point will not stand, fuse a second layer of interfacing inside the crown, or slip a rolled piece of thin plastic sheet or a length of wire inside the cone to hold it up.

5. Tips & variations

• Change it by color: black with a purple band for a witch; shorten the point for a party hat; make it white or red as a base for a Santa hat.
• Add a chin strap: for small children or outdoors, a thin elastic or ribbon at each side of the brim keeps it on.
• Make it stand: felt or interfacing is the shortcut. A single layer of thin fabric will let the point flop forward.
• Size guide: measuring is surest. The child preset assumes 52 cm, the adult preset 57 cm.