How to Make a Felt Hat: Crafting Timeless Style from Wool

Have you ever dreamed of whipping up your very own chic felt hat? Well, get ready to put on your creative cap because it’s easier than you think! With just a handful of materials and a sprinkle of imagination, you can whip up a one-of-a-kind accessory that truly reflects your unique style.

Felt is not just any fabric; it’s one of the oldest textiles in the world. Its durability and versatility make it the perfect choice for hat-making. Once you master a few basic techniques to understand how to make a felt hat, you’ll be on your way to creating a fabulous piece that will turn heads wherever you go.

So, are you excited to embark on this fun-filled journey to discover how to make a hat out of felt? Let’s dive into your DIY felt hat adventure and unleash your creativity!

Millinery, the art of hat-making, has its roots in the 16th century. The term comes from “Milaner,” referring to merchants from Milan, famed for their fancy hats, gloves, and accessories. Over time, it evolved into “milliner,” meaning hat-maker.

Indeed people have been wearing head coverings for thousands of years, and traditional hat styles, which once served as indicators of social status and occupation, have gradually transformed into modern fashion statements. From the elegant top hats of the Victorian era and the stylish fedoras of the 1920s and 1930s, to the casual beanies and baseball caps of contemporary times, each style encapsulates a particular zeitgeist, but how do you make a felt hat? Let’s find out.

Many people will have childhood memories of playing with felt, happily sticking colourful geometric shapes onto paper in nursery school and proudly displaying them on the fridge. But beyond these nostalgic moments, felt is a fascinating textile with a rich and intricate history of craftsmanship and practical application.

Felted wool is created through a process of transforming loose wool fibres into a compact, resilient material. By applying a combination of moisture, heat, and mechanical agitation, the fibres interlock and compress, creating a dense fabric with extraordinary properties. This remarkable material is not just thick and warm, but incredibly durable, making it perfect for everything from DIY felt hats to Mongolian yurts.

Felted wool is one of the world’s oldest types of fabric, and according to some historians, it may even predate the practice of weaving. One story about the origin of felt goes that people would pack their sandals with wool on long walks to prevent blisters, and the movement of walking and sweat from their feet effectively produced woollen felt socks!

But from feet to foreheads, how do you make a felt hat?

To make a very basic felt Phrygian hat – similar in style to a traditional Santa hat – you’ll need a handful of simple materials and tools.

Choose Your Felt & Fabric

First, choose a suitable piece of felted wool – thick enough to hold its shape but still pliable. Aim for a piece larger than the circumference of your head so you can comfortably cut and shape it. If you want to line your hat, consider using a lightweight linen or cotton fabric.

DIY Felt Hat Making Tools

Alongside the felt, gather a measuring tape to check your head size, a fabric chalk or marking pencil to outline your pattern, and a good pair of fabric scissors for clean, precise cuts.

Sewing Supplies

If you want to know how to make a hat out of felt, you’re going to need some basic sewing supplies, such as needles and strong, matching thread, to stitch the seam and maintain the hat’s form. If you prefer a slightly more secure structure, straight pins can help hold pieces in place before sewing. While not strictly necessary, a light steam iron can help smooth and shape the felt, as well as remove any creases. Additionally, having a tailor’s tape or flexible ruler is handy for double-checking your dimensions.

Pattern

Finally, consider a simple hat pattern or a paper mock-up of your DIY felt hat to ensure accuracy. With these basic tools and materials, you can start your first felt hat project. Over time, as your confidence grows, you can explore more specialised equipment like hat blocks or felting tools, but to start out, simple is best.

To get you started, here’s a basic guide to felt hat making. Feel free to add your personal touches wherever you like, but remember, if you’re crafting with children, supervise the use of scissors, pins, steam irons, and glue.

Measure & Mark

Start by measuring your head’s circumference with a measuring tape. You’ll want your hat to be comfortable, so note down the exact measurement. Add an extra couple of centimetres to ensure a slightly roomy fit. Using fabric chalk or a fabric-safe pencil, mark this circumference as a guide on the felt.

Draft & Shape

Create a simple pattern by drawing a rough cone shape directly onto the felt, where the base of the cone matches your head measurement. If you want the Phrygian style, the top should narrow to a point that gently curves forward. If you’re unsure, try making a quick paper mock-up first and adjust as needed. Once you’re happy, carefully cut out your felt shape with fabric scissors, making sure your cuts are clean and smooth.

Pin & Sew

Fold your felt piece in half, with the good side facing inwards. Align the edges neatly and secure them with straight pins to hold everything in place. Using a sturdy needle and strong, matching thread, begin stitching the seam from the brim up to the tip of the hat. A simple back stitch or whipstitch will work fine for beginners. Remove the pins as you go, and don’t worry if your stitches aren’t perfect, most will be hidden on the inside. You’re almost there in your quest to discover how to make a felt hat.

Shape & Finish

Once stitched, turn the hat right-side out. Gently tug and manipulate the felt to emphasise the signature forward-slanting peak of the Phrygian style. You can now try on your new DIY felt hat, checking for fit and comfort. If it feels too loose, you can add a thin band of elastic or stitched-in ribbon inside the brim. If you’d like a bit more personality, consider adding simple decorative elements, like a stitched motif, a subtle trim along the edge, or even beads or buttons. Over time, as you gain confidence and skill, you can experiment with different styles, embellishments, and techniques.

Though it might sound like a tricky undertaking, answering the question ‘how do you make a felt hat’ is surprisingly approachable, even for beginners. The process is as enjoyable as it is rewarding, an opportunity to roll up your sleeves and focus on simple, hands-on tasks. With just a few basic tools and the right guidance, you’ll soon be on your way to crafting a piece of timeless style.