Whether you’re dressing up for a festive event, creating the perfect family photo, or just want to add a touch of holiday cheer, a Santa Claus hat is a must-have accessory! Our free Santa hat pattern is designed for beginners and features step-by-step instructions, making it a super quick Christmas sewing project. You can use soft minky fabric or other stretchy materials for a cozy fit, and don’t forget the fluffy pom-pom at the tip for that classic Santa look.

Materials needed to sew the Santa Claus hat

To sew a Christmas hat using our santa claus hat template, you’ll need the following:

• Main fabric for the hat, approx. 16×24″ (40×60 cm)
• Shaggy fabric for the cuff and pom-pom, approx. 10×22″ (25×55 cm)
• Some stuffing for the pom-pom

This Santa hat pattern includes two sizes: a standard size and a larger size. The standard size suitable for most people is perfect when using stretchy fabrics like minky, fleece, or French terry, for both the main hat and the cuff. If you use our kullaloo SuperSoft SHAGGY fabric for the cuff, you can still opt for this standard size, as it’s stretchy enough to provide a snug fit.

If you plan to use non-stretch fabrics, such as cotton, wool, or thick faux fur, we recommend choosing the larger size – whether you’re using it for just the cuff or for the hat pieces as well. The larger size fits comfortably on a head circumference of up to 24″ (60 cm) when paired with a thick, fluffy non-stretch faux fur cuff.

Need the perfect fabric? We’ve got you covered!

For the main hat fabric, we recommend our slightly stretchy SuperSoft SHORTY minky or our ultra-stretchy SuperSoft SQUISHY mochi minky. These fabrics provide a velvety look, are super soft and snuggly, yet lightweight enough to keep you from overheating.

For the cuff/brim and the pom-pom, we suggest our SuperSoft SHAGGY fabrics. They are slightly elastic, not too thick, but give the appearance of a fluffy, furry brim – just like Santa’s. Alternatively, you can use our faux fur FANTASTIC Furs ✶ Fuzzy Fur, which is much thicker than SHAGGY and not stretchy.

Watch the Santa hat video tutorial

If you need a visiul guide for our Christmas hat DIY, check out the following step-by-step video tutorial from our YouTube channel:

Download the free pattern for santa hat

You can download the free sewing pattern PDF for the santa hat using this link:

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Step-by-step instructions for sewing a Santa Claus hat

1. Sew the cuff

Fold the cuff fabric in half, right sides together, and sew along the short edge.

Then, fold the tube in half again, wrong sides facing. The raw edges should align, creating a double-layered cuff. Now check the fit by placing it on your head. If it’s too loose, sew another seam close to the first one to reduce the size (but keep track of how much you reduce the circumference).

2. Sew the hat

With right sides facing, pin the two hat pieces together and sew along the side edges. If you had to adjust the cuff size, make sure to adjust the seam allowance accordingly. Trim the seam allowance at the tip of the hat for easier turning.

3. Attach the cuff

Mark the center back of the hat and pin the seam of the cuff to this mark, aligning the raw edges. Tuck the entire cuff inside the hat and pin around the raw edges. Sew the cuff to the hat, stitching along the cuff fabric on the inside of the hat. Turn the hat right side out and shape the tip nicely.

4. Make the pom-pom

Use a hand sewing needle and strong thread to sew a basting stitch around the edge of the pom-pom fabric piece. Gently pull the thread to gather the fabric, leaving a long tail. Add a small amount of stuffing and pull the thread tight to form a ball. Hand stitch the opening closed. Sew the pom-pom to the tip of the hat.

4. Enjoy your Santa hat!