A witch hat is a cone sewn to a circular brim, and you can make one in an afternoon with basic sewing skills

A witch hat has two main pieces: a tall cone that forms the crown, and a flat or slightly curved circle that becomes the brim. You sew the cone closed along its seam, attach it to the brim with a needle and thread or a sewing machine, and add a band around the base to hide the seam. The whole project takes three to five hours if you are working by hand, or about two hours on a machine. You do not need a pattern—you can draft the pieces yourself using measurements and basic geometry.

The hat works best in a stiff fabric like felt, buckram, or cotton sateen. Felt is the easiest choice because it does not fray, holds its shape without interfacing, and looks finished without much effort. Black felt is traditional, but you can use any color. Avoid stretchy fabrics like jersey or knits—they will not hold the cone shape.

Key Takeaways

  • A witch hat cone is made from a sector of a circle (a pie-slice shape) that you roll and sew closed along one edge.
  • The brim is a flat circle with a hole cut in the center, sized to match the base of your cone.
  • Felt is the best fabric choice because it holds shape, does not fray, and requires no special finishing.
  • You can sew the hat by hand with a ladder stitch or backstitch, or use a sewing machine for speed.
  • A ribbon or fabric band sewn around the base where the cone meets the brim hides the seam and adds a finished look.

Measure and draft the cone pattern

Decide how tall you want the crown. A typical witch hat crown is 8 to 12 inches tall. Write down your chosen height—let's say 10 inches.

The cone is cut from a sector (pie-slice shape) of a circle. The radius of that circle equals the slant height of your finished cone. If your cone is 10 inches tall and you want the base to be 7 inches in diameter, use the Pythagorean theorem: radius squared equals height squared plus base-radius squared. That gives you a radius of about 11 inches for your pattern circle.

On paper, draw a circle with an 11-inch radius using a compass or a string pinned at the center. Mark the center point. Now measure the circumference of your finished cone base (7 inches diameter = 22 inches circumference). Divide that by the radius of your pattern circle (11 inches). That gives you the angle of your sector: about 114 degrees. Draw two straight lines from the center of your circle at that angle apart, and cut out the sector. This is your cone pattern.

Cut the cone and brim from fabric

Pin your cone pattern to your felt and cut it out carefully. Mark the two straight edges with a pen or chalk—these edges will be sewn together to form the cone seam.

For the brim, measure the diameter of your cone base (7 inches in this example). Draw a circle on your felt with that diameter as the inner hole. Make the outer circle whatever width you want for the brim—typically 3 to 4 inches wider all around. If your inner circle is 7 inches, your outer circle might be 13 to 15 inches. Cut out the brim carefully, then cut out the center hole.

You now have two pieces: the cone sector and the brim ring.

Roll and sew the cone closed

Bring the two straight edges of the cone sector together so they overlap slightly. The cone will naturally form a three-dimensional shape as you do this. Pin the edges together, making sure the point stays sharp and the base stays round.

If you are sewing by machine, use a straight stitch and sew about a quarter-inch from the edge. Start at the point and sew toward the base. If you are sewing by hand, use a backstitch or a ladder stitch, keeping your stitches small and even. Sew the entire seam closed.

Trim any excess fabric at the seam if the overlap is thick. If you used felt, the edges will not fray, so you can leave them as they are. Turn the cone right-side out if you stitched it inside-out, though felt looks the same on both sides.

Attach the cone to the brim

Place the cone upside down (point up) and slide the brim ring over it so the inner edge of the brim sits against the base of the cone. The cone base and the brim's inner hole should match in diameter. Pin them together all the way around, keeping the cone centered.

Sew the cone to the brim using a whip stitch (by hand) or a straight stitch (by machine) about a quarter-inch from the edge. Work your way around the entire circle. If you are using a machine, go slowly and pivot the fabric as you turn the curve.

Once the cone and brim are sewn together, the basic hat shape is complete. Try it on to check the fit. If the brim is too floppy, you can stiffen it by ironing it or by adding a thin layer of interfacing before you sew it to the cone.

Add a band to finish the base

Cut a strip of fabric (or ribbon) about 2 inches wide and long enough to wrap around the base of the cone with a half-inch overlap. Felt, satin, or grosgrain ribbon all work well. Black is traditional, but you can match or contrast with your hat color.

Wrap the band around the base of the cone where it meets the brim, covering the seam. Pin it in place. Sew it down by hand with a ladder stitch (which is nearly invisible) or by machine with a straight stitch close to both edges. Overlap the ends of the band and stitch them together, then fold the overlap to the inside and stitch it closed.

The band hides the seam between the cone and brim and gives the hat a polished, finished appearance.

Shape and block the hat (optional)

If your cone looks slightly crooked or the brim is not perfectly flat, you can shape it by steaming or blocking. Hang the hat over a pot of boiling water (do not let it touch the water) and let the steam relax the fabric for a minute or two. Gently reshape the cone to be straight and the brim to be level, then let it dry in that position.

Alternatively, you can block the hat by placing it on a form (a cone-shaped object or even a rolled-up towel) and letting it dry overnight. Felt holds its shape well, so this step is optional unless your hat needs correction.

Frequently Asked Questions

Can I make a witch hat without a sewing machine?

Yes. A backstitch or ladder stitch by hand works perfectly well and takes only a bit longer. Use a needle and thread that matches your fabric, and keep your stitches small and even. Hand sewing is actually easier on curves because you have more control.

What if I do not have a compass to draw the pattern circle?

Use a piece of string pinned at the center point. Tie a pencil to the other end at the radius distance you need, and draw the circle by rotating the string. Or trace around a large plate or bowl if one is close to the size you need.

Can I use fabric other than felt?

Cotton sateen, buckram, and heavyweight cotton work well because they hold shape. Avoid stretchy or thin fabrics. If you use a fabric that frays, finish the edges with a zigzag stitch or pinking shears, and consider adding interfacing to the brim to keep it stiff.

How do I make the hat stay on my head?

Sew a thin elastic cord or ribbon inside the band at the back, sized to fit snugly under your chin. Alternatively, sew a small comb or hair clip to the inside of the brim so it grips your hair.

Can I add decorations like feathers or beads?

Yes. Sew or glue decorations to the band or the cone after the hat is complete. Hot glue works on felt, or you can hand-stitch beads, feathers, or appliqués. Add them before you wear the hat so the glue or stitches have time to set.