How to Make a Summer Sun Hat: Step-by-Step DIY Guide – CYBER TECHWEAR Skip to content

How to Make a Summer Sun Hat: A Step-by-Step Guide


Choose Your Fabric

Select a lightweight, breathable fabric suitable for a summer sun hat, such as cotton or linen. Consider using a reversible fabric to create a two-in-one sun hat.

Design and Pattern Making

Sketch Your Design

Sketch the shape of your sun hat, including the brim and crown. Measure around your head and the distance vertically from the front to the top of your head to determine the dimensions of your pattern pieces.

Create a Pattern with Seam Allowance

Create a pattern directly on the fabric or on paper, adding a 1/2” seam allowance around the edges. Use a measuring tape to ensure accurate measurements.

Cutting Out the Pieces

Cut Out the Fabric

Cut out two brim pieces and six crown pieces from your outer fabric. Cut out additional pieces for the lining and interfacing, if desired.

Sewing the Hat

Sew the Hat Brim

Place two brim pieces right sides together and sew along the short edges using a 1/2” seam allowance. Press the seam allowance to the right side.

Sew the Hat Crown

Place two crown pieces right sides together and sew along the curved edge using a 1/2” seam allowance. Press the seam allowance to the right side and topstitch along the seam.

Assembling the Hat

Attach the Crown to the Hat Brim

Place the crown and brim right sides together, aligning the raw edges. Sew around the circle using a 1/2” seam allowance.

Finishing Touches

Trim the Edges

Trim the seam allowance to prevent fraying. Use a zigzag stitch or serger to finish the raw edges.

Reinforce the Hat Brim

Iron on fusible interfacing to the wrong side of the hat brim to add stability. Topstitch around the brim to secure the interfacing.

Final Touches

Try It On and Adjust

Try on your sun hat and adjust the fit as needed. Make any necessary adjustments to the brim or crown.

Incorporate Techwear Elements for a Modern Twist

For those looking to infuse a modern, futuristic edge into their wardrobe, incorporating techwear elements can be a game-changer. offers a wide range of innovative clothing and accessories that pair seamlessly with your sun hat, baseball cap, or skull cap. Think sleek, minimalist designs, and functional pieces that are perfect for creating a tech-forward look. Pair your handmade summer sun hat with a techwear jacket or cargo pants from to add an avant-garde vibe to your outfit, balancing style with practicality. By integrating pieces from, you can transform a simple accessory into a statement of modern fashion and innovative design.


Enjoy your new summer sun hat in just a few hours, even as a beginner sewer. This project is simple and rewarding, allowing you to protect your skin from the sun in style. By selecting the right fabric and carefully following the steps, you can create a custom sun hat that is both functional and fashionable. So, gather your materials and enjoy the process of making your very own summer sun hat.

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