Free Santa Sunhat sewing pattern and tutorial
Christmas in Australia is HOT. Santa hats made from wool and fleece just make you hot and sweaty! Where are the sun-smart Santa hats? You shouldn’t have to worry that your face will be as red as your Santa hat on a hot Christmas day!
I’ve never found one in the shops, so I had to make one myself. Here’s the free sewing pattern and tutorial for a Santa sunhat:
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Santa sunhat size chart
This pattern is available in multiple sizes as per the chart below. Age ranges are included as a guideline, but it is best to choose your size by measuring the person’s head circumference. With a measuring tape, measure all the way around the head, approximately where the hat will sit.
| Size | Head circumference (cm / inches) |
| Infant (6-12 months) | 45cm / 18 inches |
| Toddler (12-24 months) | 48cm / 19 inches |
| Child (3-5 years) | 51cm / 20 inches |
| Youth (6+ years)/Adult Small | 54cm / 21 inches |
| Adult Medium | 57cm / 22 inches |
| Adult Large | 60cm / 23.5 inches |
| Adult XL | 63cm / 25 inches |
Santa sunhat free pdf template
The Santa sunhat sewing pattern is currently available as a free downloadable pdf template. Get your copy of the template here:
Supplies
Red cotton fabric (I used quilting cotton)
White fleece fabric
Red grosgrain ribbon (7/8 inch wide)
Medium-weight iron-on interfacing
Polyfill stuffing
Basic sewing supplies
Instructions
- Download and print the Santa Sunhat pattern pieces (see above).
2. Cut out the following pattern pieces:
- one crown (on the fold) and two brim pieces from red quilting cotton.
- one brim from medium-weight iron-on interfacing.
- brim trim (on the fold) and pompom piece from white fleece, felt or minky.
3. Cut a piece of ribbon as per the following size chart:
| Size | Ribbon length |
| Infant (6-12 months) | 48cm / 19 inches |
| Toddler (12-24 months) | 51cm / 20 inches |
| Child (3-5 years) | 54cm / 21 inches |
| Youth (6+ years)/Adult Small | 57cm / 22 inches |
| Adult Medium | 60cm / 23.5 inches |
| Adult Large | 63cm / 25 inches |
| Adult XL | 66cm / 26 inches |
4. Iron the interfacing to the wrong side of one brim piece.
5. With right sides together, sew the side seam of the crown cone piece with a 3/8″ (1cm) seam allowance. Finish the seam with a serger, zigzag stitch or with pinking shears.
6. With right sides together, sew the short end of the brim trim piece to create a circle. Press the seam open.
7. Mark quarters on the brim trim piece on both long edges.
8. With right sides together, pin the brim trim piece to the outside edge of one brim piece, aligning the quarter marks with the notches on the brim. Sew.
9. With right sides together, sew the outside edge of the second brim piece to the other long edge of the brim trim piece, lining up the quarter marks with the notches on the brim.
10. Turn the brim right side out, lining up the centre of the brim.
11. Sew in a spiral through all layers of the brim with a 3/8″ (1cm) width between rows, starting at the centre to just inside the brim trim.
12. Turn the crown cone piece right side out. With right sides together, line up the notches on the brim with the notches, foldline and seam on the crown. Sew with a 3/8″ seam allowance.
13. Heat seal the ends of your ribbon (if necessary).
14. Align one edge of ribbon with the seam crown-brim seam, covering the seam allowance. Overlap the ribbon at the beginning/end. Sew in place through the seam allowance only.
15. Sew a long gathering stitch around the outside of the pompom piece.
16. Gently pull to gather the pompom into a ball. Stuff with a small amount of polyfill.
17. Insert end of crown cone into the opening of the pompom. Pull the gathering stitch tight, and handstitch the pompom into place.
And there you have a cute, sun-smart Santa Claus sunhat, perfect for a hot Christmas Day. No more worrying that your face will be as red as your Santa hat!
More sewing inspiration:
- Make your own felt mistletoe
- The best Christmas stocking sewing patterns
- More Christmas sewing ideas