Introduction: Witch Hat

About: Editor of the Hellosewing blog which has been sharing fresh and creative sewing ideas with readers since 2017. She is the author of the most sewing projects, ideas and product guides shared on Hellosewing. Her…

One of the most popular costumes for Halloween is by far, the witch costume. You can make it with ease, as long as you have one important part of it. The witch hat.

With the right instructions, you can sew a witch hat from scratch easily and in a short amount of time. This tutorial will give you those instructions right away. This project is fun and simple, so it’s beginner-friendly, but also interesting enough for sewing veterans to enjoy it as well. It’s also environmentally friendly because it will stop you from buying a fast fashion costume. Now get those potions and spells ready because you’re about to learn how to make a proper witch hat in a matter of minutes!

Step 1: What You'll Need

  • fabric – premium felt 1/2 yard or something equally stiffer so that the hat can keep it’s shape
  • matching thread
  • scissors (or rotary cutter and a cutting mat)
  • ruler or measuring tape
  • fabric marking pen or sewist chalk
  • iron and ironing board
  • sewing clips or pins
  • sewing machine
  • Some wire or plastic tubing (optional)


Step 2: Prepare the Pattern

Option 1: Use the free pattern template

Download and print the patterns for the brim and the cone. Make sure to print at full scale on a US letter paper.

I've made a free witch hat pattern template which fits 21-23 inch head circumference, has a 19 inch brim diameter and is 11 inches high. Cut out the pattern you made and remove any excess paper from it.

Option 2: Custom sized hat

If you need different pattern measurements, use our free witch hat measurements calculator and draw your own pattern.

Open the free witch hat pattern calculator and enter your measurements. You will need to enter three measurements:

  1. head circumference
  2. brim diameter
  3. hat height

It will calculate how big the pieces of the hat should be from that. Then just transfer those measurements to a template or draw your pieces directly on the fabric using a pin, thread and a piece of chalk. Watch the video at the end of the tutorial to see how to do that.

Step 3: ​Cut Out the Fabrics

BRIM: Use the pattern for the brim as a guide to cut out the fabric. Fold that fabric piece in half and then cut out the little portion from the center. Once you open up the fabric, you’ll see a small round hole in the middle.

CONE: Cut out the cone piece by using the pattern as a guide.

Step 4: Sew the Cone

Fold the cone in half so that the two straight edges are aligned. Keep the right sides facing inward. Pin everything in place or secure it with clips.

Sew along the two edges you aligned with a quarter-inch seam allowance. Turn the cone inside-out and push out the tip with a chopstick or the back of a pencil.

Step 5: Sew Cone and Brim Together

Set the cone on top of the brim, over the center hole. Use pins to keep the pieces in place. Sew the two together all around the cone diameter.

Step 6: Strenghten the Brim (optional)

All that’s left now is to give that brim a bit of strength so that it can stay upwards as it should. You can do this in two ways.

OPTION 1: The first and easier option is to just fold the edge of the brim inwards twice, press it, and sew it in place like that.

OPTION 2: The second option is just a tad more difficult but easy enough nonetheless. You start the same way, fold the edge and press it, but don’t sew it shut. Leave an opening and then insert a wire or a thin plastic that’s long enough to go all around the brim edge. Secure the two ends of the wire or plastic to each other. Then sew the opening shut.

Step 7: Watch the Video Tutorial

Step 8: Go Cast a Spell

This completes your DIY witch hat! I hope you liked this tutorial! What do you think about it? Were you able to make the witch hat without any difficulties? Let us know in the comment section below. Don’t go casting too many spells now!

P.S. For those of you who want to complete their costume, I have a tutorial how to make a cloak, too

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