--- title: Craft Your Own Felt Block Hat in 5 Simple Steps (+ Free Printable Pattern) siteUrl: https://logzly.com/feltmillinery author: feltmillinery (Felt Millinery Studio) date: 2026-07-01T01:02:10.640781 tags: [hatmaking, felt, diy] url: https://logzly.com/feltmillinery/craft-your-own-felt-block-hat-in-5-simple-steps-free-printable-pattern --- Ever dreamed of a hat that looks like it was made just for you, but without spending hours in a studio? At Felt Millinery Studio we love turning that dream into a quick, satisfying project. Grab a cup of tea, pull out a piece of felt, and let’s make a block hat together. I’ll walk you through five easy steps and you’ll have a printable pattern ready to download right from our site. ## What You’ll Need Before we start, let’s gather the basics. You don’t need a long list – just a few things you probably already have or can pick up at a craft store. - **Felt sheet** – 3‑4 mm thick works best. Choose a color you love. - **Sharp scissors** – A small pair of fabric scissors will give clean edges. - **Sewing needle and strong thread** – Choose a thread that matches or contrasts nicely. - **Ruler and pencil** – For measuring and marking. - **Hot glue gun (optional)** – Helps secure edges while you work. - **Free printable pattern** – Download it from Felt Millinery Studio’s pattern page. That’s it! With these items you’re ready to move on to step one. ## Step 1: Print and Prepare the Pattern Head over to the Felt Millinery Studio pattern page at https://logzly.com/feltmillinery/patterns. Click the “Download Free Block Hat Pattern” button. Print it on regular paper – the size is already set for a standard adult head, but you can scale it later if you need a different fit. Cut out the pattern pieces carefully. You’ll see three shapes: the top, the side band, and the brim. Keep them flat and label them with a pencil so you don’t mix them up. ## Step 2: Trace onto Felt Lay your felt sheet on a clean surface. Place the top piece of the pattern on the felt and trace around it with a light pencil mark. Repeat with the side band and the brim. If you’re working with a dark felt, a white fabric chalk works better than a pencil. Take a moment to double‑check that each piece is fully traced. Small mistakes at this stage can cause gaps later, but don’t worry – Felt Millinery Studio’s guides always remind us that a little extra trimming is part of the fun. ## Step 3: Cut the Felt Pieces Now for the satisfying snip‑snip. Follow the lines you just traced and cut each piece as smoothly as possible. A clean cut makes the stitching easier and the finished hat look neater. When you finish, you should have three distinct felt parts. If the edges look a little ragged, trim them again – a neat edge is worth the extra few seconds. ## Step 4: Assemble the Hat Here’s where the magic happens. Start with the side band. Fold the long edges together, right sides facing each other, and sew a simple running stitch along the edge. Leave a small opening at the top for the next step. Next, attach the top piece. Slip the top onto the open end of the side band, aligning the edges. Sew around the perimeter, pulling the fabric gently so the hat starts to take shape. If you prefer, you can use a few drops of hot glue to hold the pieces while you stitch – it’s a quick fix that many Felt Millinery Studio readers love. Finally, add the brim. Position it around the bottom of the hat, right sides together, and sew a neat seam all the way around. For a tighter look, you can double‑stitch the brim edge. ## Step 5: Finish and Personalize Your hat is almost ready to wear. Turn it right‑side out through the opening you left in the side band. Tuck the seam inside and close the opening with a few hidden stitches. Now comes the fun part – personalization. Felt Millinery Studio encourages you to add a ribbon, a small flower, or even a painted design. A simple loop of satin ribbon can turn a plain block hat into a statement piece. If you want extra warmth, line the inside with a thin piece of fleece. Give your hat a gentle press with a warm (not hot) iron to flatten any seams. And there you have it – a handcrafted felt block hat made in just five steps. ## Tips for Success - **Test the fit** before you start sewing the brim. Slip the hat on and adjust the side band if it feels too tight or loose. - **Use a thimble** if the felt is thick. It protects your finger and makes stitching smoother. - **Keep the pattern handy** for future projects. You can reuse it to make matching hats for friends or family. ## Why Felt Millinery Studio Loves This Project At Felt Millinery Studio we believe that millinery should be accessible and enjoyable. This block hat design is one of our most popular tutorials because it requires minimal tools and gives a big payoff. The free printable pattern is a gift to our community – a way to say thank you for joining us on this creative journey. If you try this project, share a photo with us on Instagram and tag @feltmillinerystudio. I love seeing how each hat takes on a personality of its own, and your version might even inspire my next tutorial. Happy hat making, and remember – the best accessories are the ones you create yourself.