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<!DOCTYPE HTML>
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<head>
<title>LearnMYOG Packlite Hat</title>
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<meta name="description" content="Create Your Own Packlite Hat: A Lightweight, Packable Solution for Outdoor Adventures
The Packlite Hat pattern by LearnMYOG offers two versatile styles—an ultralight 5-panel and a classic 6-panel dad hat. Designed for hikers, trail runners, and endurance athletes, this pattern is ideal for crafting breathable, technical headwear from fabrics like taslan nylon and sport mesh. With a simplified design that works well with most home sewing machines, the Packlite Hat features a packable brim, customizable fit, and options for ponytail-friendly back closures. Elevate your outdoor gear with this easy-to-follow sewing pattern, perfect for your next DIY adventure.">
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<h1>Packlite Hat</h1>
<h3>Craft Your Own Ultralight Hat for Active Adventures</h3>
</div>
<!-- Gallery -->
<div class="gallery style1 small">
<article class="youtube">
<a href="https://www.youtube.com/embed/Jm1YthWl6ag" class="image" data-poptrox="iframe,775x436">
<img style="object-position: right;" src="images/packlitehats/thumbs/thumb.jpg" title="Sewalong Tips & Tricks" loading="lazy" />
<div class="play-button"></div>
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</article>
<article>
<a href="images/packlitehats/whitefront.jpg" class="image">
<img src="images/packlitehats/thumbs/whitefront.jpg" title="Foam brim thats packable and durable" loading="lazy" /></a>
</article>
<article>
<a href="images/packlitehats/whiteback.jpg" class="image">
<img src="images/packlitehats/thumbs/whiteback.jpg" title="Adjustable closure with multiple options" loading="lazy" /></a>
</article>
<article>
<a href="images/packlitehats/underside.jpg" class="image">
<img src="images/packlitehats/thumbs/underside.jpg" title="Clean interior finish techniques described" loading="lazy" /></a>
</article>
<article>
<a href="images/packlitehats/IMG_1136.jpg" class="image">
<img src="images/packlitehats/thumbs/IMG_1136.jpg" title="Packlite 5-Panel Hat" loading="lazy" /></a>
</article>
<article>
<a href="images/packlitehats/IMG_1137.jpg" class="image">
<img src="images/packlitehats/thumbs/IMG_1137.jpg" title="Adjustable fit with common gear-making hardware" loading="lazy" /></a>
</article>
<article>
<a href="images/packlitehats/IMG_1138.jpg" class="image">
<img src="images/packlitehats/thumbs/IMG_1138.jpg" title="Sew At Home with Lightweight Technical Fabrics" loading="lazy" /></a>
</article>
<article>
<a href="images/packlitehats/hat6panel.jpg" class="image">
<img src="images/packlitehats/thumbs/hat6panel.jpg" title="Packlite 6-Panel Hat Included" loading="lazy" /></a>
</article>
<article>
<a href="images/packlitehats/IMG_1024.jpg" class="image">
<img src="images/packlitehats/thumbs/IMG_1024.jpg" title="Multiple Brims Lengths and Material Options" loading="lazy" /></a>
</article>
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<a href="images/packlitehats/IMG_1022.jpg" class="image">
<img src="images/packlitehats/thumbs/IMG_1022.jpg" title="Multiple Sizes for Tailored Fit" loading="lazy" /></a>
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<!-- <header><h3>Introducing the Skyline Sun Hoodie: Your Ultimate Adventure Companion</h3></header> -->
<div class="content">
<h3>You’ll Love Your Packlite Hat</h3>
<p>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.</p>
<ul>
<li><strong>Pattern Variations:</strong> Includes two styles! A sporty 5-panel and a 6-panel camp hat. Three brim length options provide extra flexibility and style.</li>
<li><strong>Versatile Sizing:</strong> 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.</li>
<li><strong>DIY-Friendly Design:</strong> 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.</li>
<li><strong>Active Lifestyle Ready:</strong> 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.</li>
<li><strong>Unstructured Design:</strong> 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.</li>
<li><strong>Material Options:</strong> 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.</li>
</ul>
</div>
</div>
<ul class="icons">
<li><img class="image small" src="images/packlitehats/hat5.png" alt="5-panel hat sketch" /><p>5-Panel Hat</p></li>
<li><img class="image small" src="images/packlitehats/hat6.png" alt="6-panel hat sketch" /><p>6-Panel Hat</p></li>
<li><img class="image small" src="images/packlitehats/profile.png" alt="two height profiles" /><p>Multiple Sizes for Perfect Fit</p></li>
<li><img class="image small" src="images/packlitehats/brimsz.png" alt="three brims included" /><p>Three Brim Options</p></li>
</ul>
</section>
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<section>
<header>
<h3>Digital Sewing Pattern</h3>
</header>
<div class="content">
<ul>
<li><strong>Clear, Illustrated Instructions:</strong> Confidently bring your project to life with easy-to-follow, illustrated guides and high-contrast diagrams that simplify every step.</li>
<li><strong>Tailored Sizing Choices:</strong> 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.</li>
<li><strong>Seam Allowances Included for Precision:</strong> Enjoy a smooth sewing experience with pre-included seam allowances on every panel, ensuring your hat has professional-quality seams and finishes.</li>
<li><strong>Print-Friendly at Home:</strong> The pattern is optimized for standard Letter or A4 paper, making it easy to print at home and assemble with minimal hassle.</li>
<li><strong>Projector Sewing Compatible:</strong> 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 <a href="https://www.patternprojector.com/">Pattern Projector</a> app! Users can upload the large format pattern file to enjoy full compatibility with the pattern cutting specific tools available in the app.</li>
</ul>
<!--<h3>Get Notified When the Packlite Hat Pattern Launches</h3>
<p>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.</p>
<a href="https://payhip.com/b/AB7ak" target="_blank" class="button primary icon solid fa-envelope" style="font-size: 100%">Join the Waitlist</a>
<p>Be the first to know and secure your copy—no spam, just updates!</p> -->
<h3>Don't Miss the Limited Time Discount!</h3>
<a href="https://shop.learnmyog.com/shop/p/packlite-hat" class="button primary icon solid fa-credit-card" style="font-size: 100%"><s>$15</s> $10</a>
<p>All LearnMYOG patterns are for <strong>personal, non-commercial use only.</strong></p>
<p>We're excited to invite you to shop at our new and improved store, where you can enjoy a smoother checkout experience and flexible payment options, including PayPal and many other methods.</p>
<p>If you encounter any issues or prefer to use our previous platform, you can still make purchases at <a href="https://payhip.com/b/SV7iz">Payhip</a>.</p>
<p>As always, if you have any questions or need assistance, don’t hesitate to reach out—we’re here to help!</p>
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<h3>Materials</h3>
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<div class="content">
<p>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.</p>
<h4>Key Considerations</h4>
<ul>
<li><strong>Breathability and Moisture-Wicking:</strong> Look for fabrics like ripstop nylon, taslan nylon, and polyester mesh that allow airflow and wick moisture away for optimal comfort during intense activities.</li>
<li><strong>UPF Protection:</strong> Fabrics with a UPF rating block harmful UV rays. For outdoor sports, a UPF rating of 30-50+ is ideal for enhanced sun protection.</li>
<li><strong>Water-Resistance (DWR Coating):</strong> Durable Water Repellent (DWR) coatings help shed light rain and moisture, making these fabrics excellent for unpredictable weather.</li>
</ul>
<h4>Fabric Recommendations</h4>
<ul>
<li><strong>Supplex Nylon:</strong> Lightweight yet durable, Supplex nylon (aka taslan) is ideal for ultralight projects and has a matte finish that resists snags.</li>
<li><strong>Ripstop Nylon:</strong> A classic choice for outdoor gear, ripstop offers strength and breathability. Versions with DWR coatings add extra water resistance.</li>
<li><strong>Breathable Mesh:</strong> 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.</li>
</ul>
<h4>Brim Material</h4>
<p><strong>3mm EVA Foam:</strong> Optimal for a pliable, packable brim that holds its shape even after being stowed. EVA foam is lightweight, durable, and easy to work with.</p>
<h4>Sweatband Material</h4>
<ul><li><strong>Performance Knit or Wicking Jersey:</strong> 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.</li>
<li><strong>Pre-Made Hat Sweatband:</strong> 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.</li></ul>
<h4>Back Closure Options</h4>
<ul>
<li><strong>Webbing with Ladder Lock or Center Release Buckle:</strong> 1/2" lightweight webbing paired with a plastic ladder lock or center release buckle offers a secure and adjustable fit.</li>
<li><strong>Shock Cord with Cord Lock:</strong> For a minimalist closure, shock cord combined with a cord lock and metal eyelet provides a stretchy and adaptable fit.</li>
</ul>
<div class="items style3 small">
<section>
<a href="https://discoveryfabrics.com/LearnMYOG" target="_blank" ><img class="partner desaturated fit" src="images/shared/partners/200/discoveryfabrics.webp" alt="Discovery Fabrics" /></a>
</section>
<section>
<a href="https://ripstopbytheroll.com/?rfsn=4608557.2d546b9" target="_blank" ><img class="partner desaturated fit" src="images/shared/partners/200/RBTR.webp" alt="Ripstop by the Roll" /></a>
</section>
<section>
<a href="https://questoutfitters.com/" target="_blank" ><img class="partner desaturated fit" src="images/shared/partners/200/questoutfitters.webp" alt="Quest Outfitters" /></a>
</section>
</div>
<h4>Minimum Yardage Recommendation</h4>
<div class="table-wrapper">
<table>
<thead>
<tr>
<th>Material</th>
<th>Amount</th>
<th>Product Recommendation</th>
</tr>
</thead>
<tbody>
<tr>
<td>Main Fabric</td>
<td>1/4 yard</td>
<td>Supplex Nylon (taslan), Breathable Ripstop Nylon, Stretch Woven Fabric, Monolite Mesh, or Printed Cotton Canvas. So many options!</td>
</tr>
<tr>
<td>Brim Material</td>
<td>5"x8"</td>
<td><a href="https://amzn.to/4dvBCjs" target="_blank">3mm EVA Foam Sheet</a> </td>
</tr>
<tr>
<td>Sweatband</td>
<td>1/4 yard</td>
<td><a href="https://amzn.to/3YS4bmr" target="_blank">Moisture-Wicking Activewear Knit Fabric</a> or a
<a href="https://amzn.to/3YOx9Ux" target="_blank">Pre-Made Hat Sweatband</a></td>
</tr>
<tr>
<td>Front Stabilizer</td>
<td>3" x 8"</td>
<td><a href="https://ripstopbytheroll.com/products/3-4-oz-pocket-mesh?rfsn=4608557.2d546b9">Pocket mesh</a> or any durable low stretch mesh such as <a href="https://www.questoutfitters.com/mesh_fabrics.htm#POLYMESH1">polymesh</a></td>
<tr>
<td>Back Closure</td>
<td>9"</td>
<td><a href="https://ripstopbytheroll.com/products/ultralight-ladder-loc-adjusters?rfsn=4608557.2d546b9" target="_blank">1/2" Webbing + Ladder Lock Set</a></td>
</tr>
</tbody>
<tfoot><tr><td colspan="3"></td></tr></tfoot>
</table>
<p class="disclosure">Qualified purchases support LearnMYOG.com at no additional cost to you. See <a href="/about.html#disclosures">Disclosures</a> for more information.</p>
<h4>Suggested needle and thread pairing</h4>
<ul class="alt" >
<li>🪡 Microtex size 80/12 or 90/14</li>
<li>🧵 Gutermann MARA 100 or MARA 70 - Tex 35-40 polyester thread</li>
</ul>
</div>
</div>
</section>
<section>
<header>
<h3>Pattern Difficulty</h3>
</header>
<div class="content">
<span class="image right align-center"><a href="/articles/sewingUltralightFabrics.html" target="_blank">
<img class="image right" src="images/articles/ulfabrics.jpg" alt="sewing ul fabrics" /></a>
<caption>Sewing UL Fabrics</caption></span>
<p>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.</p>
<p>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 <a href="/articles/sewingUltralightFabrics.html">Mastering Techniques for Sewing Ultralight Apparel Fabrics</a> 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.</p>
<ul class="icons align-center">
<li><a href="https://youtu.be/Jm1YthWl6ag" target="_blank" class="youtube">
<img class="image small" src="images/packlitehats/thumbs/thumb.jpg" title="Watch the Step-by-Step Sewalong Video" loading="lazy" />
<div class="play-button"></div>
</a>
<p>Sewalong Tips & Tricks</p>
</li>
</ul>
</div>
</section>
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