Make a kids sun hat with Freckles and co digital sewing pattern
Craft Everything Seasonal Sewing

Make – Kids Sun Hat

Make one of these super cute and handy kids sun hats in 5 easy steps with my downloadable PDF pattern. I have used this pattern lots of times to make the cutest hats for my own kids and friends children, and the best bit, they are reversible!

Sizing is suitable for 3months – 9yrs

XS / 3-12months / 44cm head circumference
S / 1-3yrs  / 46cm head circumference
M / 3-6yrs / 48cm head circumference
L / 6-9yrs / 51cm head circumference

Looking for a bigger pattern see HERE

If you don’t have the sewing pattern already download it in my Etsy shop HERE.

You can also watch these instructions on my YouTube channel.

Freckles Kids Sun Hat sewing pattern PDF  download

Before you start you will need the following kit:

  • Cotton Fabric 1 – 25cm
  • Cotton Fabric 2 – 25cm
  • Interfacing (Optional to stiffen)
  • Thread – Seen on the brim
  • Pins
  • Sewing needle or machine
  • Sharp clean scissors


Start by cutting out your pattern templates using paper scissors.

If you are cutting the smallest size, consider photo copying the pattern or fold down the bigger sizes to make a bigger one at a later date.

Next cut out all fabrics pieces required, be mindful of pattern and grain direction. Pin and cut using sharp fabric scissors. Seam allowances are included in the pattern so we can cut close to the edges.

You should end up with 12 cap segments and 4 brim pieces in total.

2 Making the CAP

Fabric 1 – Sew 3 segments together to create 1 half of a cap, sew another 3 segments together in the same way and then join the 2 halves to finish one cap.

Repeat these steps with Fabric 2

Top tip: Press seams open as you go.

3 Making the BRIM

Fabric 1 – Sew the ends of each brim right sides together to form a circle with a hole in the middle (Optional – use a light weight interfacing to make the brim stiffer).

Press seams open and then join the brim to the cap. Ease on the brim by matching seams and pinning lots.

Repeat these steps with Fabric 2

4 JOINING the 2 hats together

Place both hats right sides together and pin matching seams. Join all the way around the edge of the brim leaving 3cm gap.

Turn your hat through the hole you left and press well with the iron.


Top stitch all the way around the brim edge 0.3cm allowance, closing up the hole.

Secure the 2 hats together with another top stitch further up the brim and/or hand sew the top center of the caps together.

And you are finished Congratulations! I would love to see your hat please share on social media @frecklesandcocraft #frecklescraft

Looking for a bigger size? see my adults version of this pattern on Etsy (click the image below)

You can also watch these instructions on YouTube

Happy Sewing

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