DIY Mini Witch Hat for Halloween + Free Sewing Pattern

Halloween is the perfect time to get creative with handmade decorations, and this mini decorative witch hat is a quick and fun project you can sew at home. In this post, I’ll walk you step-by-step through how to make your own cute witch hat, and I’m including a free PDF pattern so you can follow along easily. Whether you’re crafting for your Halloween mantel, party decor, or love seasonal sewing projects, this tutorial makes it simple and enjoyable.

I originally designed a larger quilted witch hat pattern for my Etsy shop. Still, as I was making one, I started thinking about how fun a mini version could be—just a little hat, small enough to tuck on a shelf or sneak into a Halloween display. I loved the idea of adding a tiny, handmade touch to my own holiday decor.

Once I made it, I knew I had to share the pattern with anyone who might want a simple, festive Halloween project — so here it is! Now that you know a little about how this mini witch hat came to be, let’s get sewing! I’ve broken the process down into simple steps, and I’ve included a free PDF pattern to make it easy to follow along. Don’t worry if you’re a beginner — this project is totally doable, and I’ve included tips and tricks I learned while making my own hats.

Supplies

Instructions:

Step 1: Download the Free PDF Pattern

Start by downloading the free PDF mini-witch hat pattern and printing it out. I recommend printing on card stock instead of regular printer paper — it’s sturdier and easier to trace or cut around. Plus, it won’t fold or bend if you want to make several hats.

Cut out your pattern pieces, including the small circle with the dashed line in the center of the brim.

Step 2: Cut Your Fabric

Trace the brim and crown pattern pieces onto your main fabric and fusible fleece, then cut out all four pieces. You can also use a small rotary cutter if that’s easier. Don’t forget to cut out the small center circle from the main fabric brim piece and the fusible fleece brim piece. Next, cut one brim piece from your lining fabric, but leave the center circle intact.

Tip: Follow the manufacturer’s instructions to fuse the fleece to the main fabric before cutting it. It saves time and keeps everything aligned.

Once cut, follow the manufacturer’s instructions and iron the fusible fleece to the back of the main fabric brim pieces. The lining piece does not get fusible fleece.

Step 3: Sew the Witch Hat Crown

Set the brim pieces aside. Fold the crown piece in half, right sides together, straight edges aligned. Clip in place and sew along the straight edge with a ½” seam allowance, remembering to back stitch at the start and finish.

Trim excess seam allowance, getting as close to the seam as possible without cutting it. Clip the tip carefully — don’t cut the seam.

Use a turning tool to push out the hat tip. Go gently — trust me, pushing too hard can tear a hole (learned that the hard way!). If the tip doesn’t come out enough, clip the seam slightly more. Turn the crown right-side out. The fusible fleece should give it nice structure. It may cave a bit along the seam, but don’t worry — it will even out once it’s fully assembled.

Step 4: Attach the Brim

Grab the main fabric brim piece (with fusible fleece and center hole). Slip the crown through the hole. Fold the brim up around the crown so right sides are together. Pin the edges carefully as you go.

Tip: Pins work better than clips on the curved edge — they help keep everything from slipping while sewing.

Sew the crown to the brim with a ¼” seam allowance. Go slowly, flattening the brim under your machine foot to prevent bunching. Trim the seam close to the stitching, but don’t cut the stitching!

Step 5: Finish Assembling the Hat

Almost done! Push the crown slightly back through the brim hole so you can attach the lining piece. Turn the hat upside down and pin the lining to the bottom of the crown. Right sides together if your lining has a pattern.

Sew around the edge with a ½” seam allowance, leaving a 1½” opening for turning. Use pinking shears to trim excess seam allowance around the brim. No pinking shears? Make small clips around the curve to help the brim lay flat.

Turn the hat right-side out through the opening. Start by pulling the tip of the crown through first, then work the rest of the hat out. Use a turning tool or scissors to push out the brim seam and iron flat.

Tip: If you want a stiffer crown, you can add a little polyester filling or cotton balls through the opening. My fabric held up fine without extra stuffing.

Step 6: Add Finishing Touches

Top stitch along the brim to close the turning opening. I learned using a slightly longer stitch here keeps the edge smooth — shorter stitches made my brim a little wavy.

Iron the brim flat — a light starch can help. Now get creative! I added a small ribbon bow to one hat and glued tiny black spiders to another.

Display your mini witch hats anywhere you like — a centerpiece, bookshelf, mantle, tray, or even string them together as a witch hat garland.

What will you do with yours?

I’d love to see your mini witch hats! Share a photo on Instagram and tag me using #wakeearlycrafts or drop a picture in the comments below. I can’t wait to see your witch hats!