Big brim hat pattern – 3 brim sizes!


Digital PDF pattern set to help you make your own cosplay props! Do you want to make a hat with a big brim out of foam? Now you can!

Read on…


Digital patterns (PDF) that you can print out and use to make your own (cosplay) prop hat. They are digital files, so there is no physical pattern that I send to you. You will need to download the file to your computer and work with it from there.

If you purchase this PDF, you can immediatly download it and print it to help make your own props. This pattern set does not include a written tutorial book, but all the instructions you will need are written on the pattern itself. Some basic crafting experience is advised when working with this pattern.

I advice to make this hat using 5mm thick EVAfoam. Both low density and high density EVA foam can be used. It will affect however how floppy the brim will be in the end. So that’s completely up to you!

The pattern comes with different sizes of the brim. One for a very large brim (really gigantic), one with still a big brim, and another with a more normal sized brim. So there’s plenty of options with this pattern.

The top of the hat fits well over an adult size head. If you have a larger head or if you want to wear a big wig underneath, then just widen the ‘top of hat’ pattern piece so the part that goes over your head will be bigger.


This digital PDF pattern set includes blueprints for the following:

  • Hat with a brim of 73 cm (28,75 inches) in diameter
  • Hat with a brim of 56 cm (22 inches) in diameter
  • Hat with a brim of 36 cm (14,5 inches) in diameter

Download includes:

PDF file with the pattern in dinA4 size (12 pages)
PDF file with the pattern in Letter size (12 pages)


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