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 sporty 5-panel and a 6-panel camp hat. Three brim length options provide extra flexibility and style.
  • Versatile Sizing: With three head size options ranging from 21-25 inches (53-64 cm) and adjustable features, this hat ensures a perfect fit. It can also be customized for ponytail access or different closure styles.
  • 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.
  • 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

    Multiple Sizes for Perfect Fit

  • three brims included

    Three Brim Options

Digital Sewing Pattern

  • Clear, Illustrated Instructions: Confidently bring your project to life with easy-to-follow, illustrated guides and high-contrast diagrams that simplify every step.
  • Tailored Sizing Choices: This sewing pattern offers three distinct size options, designed to accommodate head circumferences from 21 inches (53 cm) to 25 inches (63 cm). Both the 5-panel and 6-panel patterns include these tailored sizes, ensuring a custom fit that’s adjustable for various head shapes and preferences.
  • 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.

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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.
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 5"x8" 3mm EVA Foam Sheet
Sweatband 1/4 yard Moisture-Wicking Activewear Knit Fabric or a Pre-Made Hat Sweatband
Front Stabilizer 3" x 8" Pocket mesh or any durable low stretch mesh such as polymesh
Back Closure 9" 1/2" Webbing + Ladder Lock Set

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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.

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    Sewalong Tips & Tricks