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NOTE - This is a digital pattern ONLY. If you want the hardcopy with the digital pattern, click here.
Patterns take the guesswork out of the making process. We’ve all been halfway through a project and realized that we forgot a crucial part.
With the patterns from Learn MYOG you can bet on yourself to make kick ass items.
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 our 3.4 oz Taslan Nylon, Lycra PowerMesh, and EVA foam—yet it can accommodate specialty hat materials like buckram stiffener and pre-made sweatband if available.
Starting new projects should be exciting, not scary. Take the scare away with this pattern and experience the next level in summer fashion and sun protection with the Packlite Hat!
Downloadable PDF sewing pattern includes
- 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.
NOTE - This is a digital product that will be delivered automatically to the email you input at checkout. If you haven't received your pattern package within 24 hours of checkout, please contact us directly
LearnMYOG patterns are for personal, non-commercial use only.
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Sewing Skill Level - Advanced Beginner
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.
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.
Suggested Fabrics:
