Packlite Hat

Craft Your Own Ultralight Hat for Active Adventures

You’ll Love Your PackLite Hat

The PackLite Hat pattern brings you the freedom to create ultralight, performance-driven headwear with a customizable touch. Whether you’re trail running, fishing, or embarking on a multi-day hike, this hat delivers on comfort, packability, and style.

  • Pattern Variations: Includes two styles—a 5-panel and a 6-panel hat—each with low and mid-profile height options, so you can tailor the fit to your preferences. Three brim length options provide extra flexibility and style.
  • DIY-Friendly Design: No special machine attachments or hat-making tools are required. Hats are difficult to sew well, but this pattern simplifies the process and can be sewn on any home sewing machine.
  • Active Lifestyle Ready: Using the recommended materials, the hat is machine washable and designed with a soft brim, making it easy to pack, durable enough for rough use, and comfortable for all-day wear. It’s an ideal companion for any outdoor activity, whether you’re trail running, hiking, or on the move.
  • Unstructured Design: The hat’s unstructured construction keeps weight to a minimum and makes it easily washable. An optional stiffener is also included for those who prefer a defined shape and low-profile trucker style.
  • Universal Fit: With an adjustable size that fits most, the hat can be further customized for ponytail access or different closure styles.
  • Material Options: The pattern is optimized for fabrics commonly used in outdoor gear making—like Supplex nylon, performance knits, and EVA foam—yet it can accommodate specialty hat materials like buckram stiffener and pre-made sweatband if available.
  • 5-panel hat sketch

    5-Panel Hat

  • 6-panel hat sketch

    6-Panel Hat

  • two height profiles

    Low and Mid Profiles

  • three brims included

    Three Brim Options

Digital Sewing Pattern

  • Clear, Step-by-Step Instructions: Confidently bring your project to life with easy-to-follow, illustrated guides and high-contrast diagrams that simplify every step.
  • Adjustable Fit for Most Sizes: Designed to accommodate head sizes from 21.5 (54.6 cm) to 23.5 (59.7 cm) inches in circumference, this one-size-fits-most hat is fully adjustable for a tailored fit.
  • Seam Allowances Included for Precision: Enjoy a smooth sewing experience with pre-included seam allowances on every panel, ensuring your hat has professional-quality seams and finishes.
  • Print-Friendly at Home: The pattern is optimized for standard Letter or A4 paper, making it easy to print at home and assemble with minimal hassle.
  • Projector Sewing Compatible: Avoid the tedious printing and taping by projecting the selectable size pattern directly onto your fabric. Seamlessly integrate your sewing workflow with the free and open-source Pattern Projector app! Users can upload the large format pattern file to enjoy full compatibility with the pattern cutting specific tools available in the app.

Get Notified When the PackLite Hat Pattern Launches

Interested in getting your hands on the new PackLite Hat pattern? Join the no-commitment waitlist today! You’ll receive no more than three emails—just the essentials to keep you in the loop and notify you when the pattern is ready.

Join the Waitlist

Be the first to know and secure your copy—no spam, just updates!

Materials

When selecting materials for sewing the PackLite Hat, especially for outdoor use, key factors include breathability, sun protection, and durability. This guide helps you choose fabrics and notions that balance comfort, functionality, and ease of sewing for activities like trail running, hiking, and other endurance sports.

Key Considerations

  • Breathability and Moisture-Wicking: Look for fabrics like ripstop nylon, taslan nylon, and polyester mesh that allow airflow and wick moisture away for optimal comfort during intense activities.
  • UPF Protection: Fabrics with a UPF rating block harmful UV rays. For outdoor sports, a UPF rating of 30-50+ is ideal for enhanced sun protection.
  • Water-Resistance (DWR Coating): Durable Water Repellent (DWR) coatings help shed light rain and moisture, making these fabrics excellent for unpredictable weather.

Fabric Recommendations

  • Supplex Nylon: Lightweight yet durable, Supplex nylon (aka taslan) is ideal for ultralight projects and has a matte finish that resists snags.
  • Ripstop Nylon: A classic choice for outdoor gear, ripstop offers strength and breathability. Versions with DWR coatings add extra water resistance.
  • Breathable Mesh: Perfect for side panels or the back portion of the hat, breathable mesh keeps you cool during high-output activities. Nylon or polyester mesh fabrics ideal.

Brim Material

3mm EVA Foam: Optimal for a pliable, packable brim that holds its shape even after being stowed. EVA foam is lightweight, durable, and easy to work with.

Sweatband Material

  • Performance Knit or Wicking Jersey: These soft, moisture-wicking, and quick-drying fabrics provide the best comfort for interior sweatbands, efficiently managing sweat during active use. They’re lightweight and breathable, making them ideal for ultralight, performance-focused designs.
  • Pre-Made Hat Sweatband: For a more traditional approach, pre-made hat sweatbands are a viable option. While they add some weight and can become less comfortable when saturated, they offer a consistent fit and structure. Pre-made bands are especially useful if you prefer a ready-to-go solution.

Back Closure Options

  • Webbing with Ladder Lock or Center Release Buckle: 1/2" lightweight webbing paired with a plastic ladder lock or center release buckle offers a secure and adjustable fit.
  • Shock Cord with Cord Lock: For a minimalist closure, shock cord combined with a cord lock and metal eyelet provides a stretchy and adaptable fit.

Interior Seam Finishing

Finishing the interior seams with flat binding can be tricky without specialty attachments or an industrial machine with a dual needle. Although twin-needle sewing is possible, it often causes fabric tunneling with the lightweight materials recommended for this design. For better results, it’s suggested to use a serger or an overedge zigzag stitch while minimizing topstitching.

Discovery Fabrics
Ripstop by the Roll
Quest Outfitters

Minimum Yardage Recommendation

Material Amount Product Recommendation
Main Fabric 1/4 yard Supplex Nylon (taslan), Breathable Ripstop Nylon, Stretch Woven Fabric, Monolite Mesh, or Printed Cotton Canvas. So many options!
Brim Material 8"x6" 3mm EVA Foam Sheet
Sweatband 1/4 yard Moisture-Wicking Activewear Knit Fabric or a Pre-Made Hat Sweatband
Front Panel Stiffener 6 inches Pocket mesh or any durable low stretch mesh such as polymesh
Back Closure 10 inches 1/2" Webbing + Ladder Lock Set

Qualified purchases support LearnMYOG.com at no additional cost to you. See Disclosures for more information.

Suggested needle and thread pairing

  • 🪡 Microtex size 80/12 or 90/14
  • 🧵 Gutermann MARA 100 or MARA 70 - Tex 35-40 polyester thread

Pattern Difficulty

sewing ul fabrics Sewing UL Fabrics

This pattern is rated for advanced beginners or intermediate sewists due to its technical requirements and precise construction. You'll need a zipper foot (presser foot) for sewing close to tight edges and a walking foot attachment can be a game-changer, especially when working with slippery or lightweight fabrics. A serger is strongly recommended for cleanly finishing interior seams, ensuring durability and a polished look.

This project offers a great opportunity to elevate your sewing skills by tackling curved seams, precision topstitching, and working with ultralight fabrics. The design is optimized for lightweight, breathable materials, which require extra attention to detail. If you’re new to sewing these types of fabrics, we recommend reading Mastering Techniques for Sewing Ultralight Apparel Fabrics for valuable tips on handling uncoated, technical textiles. Though this pattern is challenging, it's also highly rewarding, producing a versatile and functional hat that’s perfect for outdoor adventures.

  •

    Sewalong Tips & Tricks