sew a sun hat

Master the Effortless Craft: Sew a Sun Hat Like a Pro

This blog shows how to make a basic sun hat using just a few materials. It’s a perfect project for beginners!

  • Sun hats protect your face and neck from harmful rays
  • You’ll learn to sew a round cap with a wide brim
  • This pattern can be adjusted to fit any head size
  • With some boning, the brim will hold its curved shape nicely
  • It’s a great way to refashion and reuse fabric scraps

What You’ll Need

Gather these supplies before starting:

  • 1⁄2 yard of cotton fabric for the hat top
  • 1 yard of fabric for the brim (choose a heavier material)
  • 1⁄4 yard of lightweight fusible interfacing
  • 2 yards of 1⁄4 inch millinery boning or plastic-covered wire
  • Basic sewing tools (machine, scissors, pins, etc.)

That’s it! With just some fabric and a few notions, you’ll be able to custom-make the perfect sun hat.

Sizing Your Pattern

Sizing Your Pattern
Photo credit: freepik

Most sun hat patterns are meant for an average adult’s head size. But what if you need to make one much bigger or smaller?

The pattern here can be easily adjusted by:

  1. Measuring around your head with a flexible tape measure
  2. Dividing that number by 3.14 to get the diameter
  3. Using that diameter measurement to cut out the circle cap top

It’s that easy to get a comfy, well-fitted sun hat made just for you!

Cutting Out the Pieces


Pattern PieceFabric to Use
Hat Top CircleCotton
BrimHeavier Fabric
Brim InterfacingFusible Interfacing

Once you have your customized diameter, use it to cut:

  • One circle from cotton fabric for the hat top
  • One circle from heavier fabric for the brim, 5 inches larger than a top circle
  • One circle of fusible interfacing, the same size as the brim piece

Having the brim cut larger than the top gives it a nice, curved shape later on.

Sewing the Hat Together

The steps are simple:

  1. Iron the brim interfacing to the wrong side of the brim fabric
  2. Sew the brim piece to the hat top piece, right sides together
  3. Clip the seam allowance in sections to allow the brim to curve
  4. Turn the right side out and press the seam
  5. Slip millinery boning or wire into the brim seam to hold its shape

Take it nice and slowly, and you’ll end up with a professional-looking sun hat! The boning in the curved brim helps the shape last.

Customizing Your Creation

With a basic pattern like this, it’s easy to add creative touches:

  • Embellish the brim with decorative stitching or appliques
  • Add contrasting fabric bands or piping around the crown
  • Sew a fabric flower, ribbon trim, or other adornment

Let your imagination go wild to design a totally unique sun hat! It’ll keep you safe from rays in style.


What materials do I need to sew a sun hat?

You’ll need fabric for the top and brim, fusible interfacing, millinery boning or wire, basic sewing supplies like scissors, pins, and a sewing machine.

How do I determine what size sun hat to make?

Measure around your head with a flexible tape measure. Divide that number by 3.14 to get the diameter size you’ll cut the top circle piece.

How do I get the brim to hold its curved shape?

Insert millinery boning or plastic-covered wire into the seam between the brim and crown. This will help the brim keep its gently curved shape.

What kind of creative touches can I add?

You can embellish it with appliques, decorative stitching, contrasting fabric bands, ribbons, fabric flowers, and more to make your sun hat truly unique.

Is making a sun hat a good project for beginners?

Yes! This sun hat pattern is very beginner-friendly. It lets you practice skills like sizing patterns, sewing curves, installing boning, and finishing details.

Do I have to use new fabric, or can I refashion old materials?

You can absolutely use fabric scraps or repurpose old garments to create a sustainable, eco-friendly sun hat! Upcycling is encouraged.

Sun Hats Made Simple

Making a custom sun hat is a perfect beginner sewing project. You learn skills like:

  • Taking head measurements and sizing a pattern
  • Cutting curved fabric pieces on the bias
  • Installing millinery boning to shape a brim
  • Finishing touches like topstitching and clipping curves

Best of all, you end up with a fashionable sun hat you can actually wear! What other basic sewing project is so useful?

Have you ever made your own sun hat before? If not, what fun design ideas do you have for making this pattern your own? Let me know in the comments!


Main image: freepik

Priti Nandy
Priti Nandy
Articles: 285

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