What Interfacing to Use for Hats (Sun Hat Brim, Bucket)

It all depends. Those are 3 words many people get tired of hearing. But that is the way it is in the sewing world. What item you use, how much of it and when to use it, all depends on the sewing project, its size, and so on.

What interfacing to use for hats: This will depend on the type of hat you are trying to make and how stiff you want it to be. A soft floppy hat needs a lightweight interface while a fedora would need a stiff interface. But not so stiff that you can’t bend the brim a bit to change his look.

To learn all about interfacing for hats just continue to read our article. It has the information you need to know about including the fact that interfacing, even for hats, cannot weigh more than the hat fabric.

Interfacing for Hat-Making

The best part about making hats is that no matter the type, there is interfacing for the hat. The trick is to make sure that the interfacing does not outweigh the hat fabric so you need to know those details to get the interfacing just right.

Interfacing for collars and facing usually is not strong enough for most hats or hat brims. You may need to go to a specialty craft interfacing as that material should be stiff enough to keep the hat’s shape.

For sun hats you may be able to use Pellon #808 non-woven craft fuse or even a Pellon shape flex which is woven. You have lots of options available to you, so take your time and search out the right interface material for your project.

Interfacing for a Hat Brim


Pellon seems to have a lot of variety when it comes to interfacing for hats. There are the previous two options and there is also the non-grain type of interfacing. The grain really isn’t important when it comes to interfacing so you do not always need to use fabric that has grain.

One thing to remember is cleaning the hat. While most hats can’t be washed, there are some that you will hand wash, or let the machine handle that duty. Any interfacing you use for those washable hats should be pre-shrunk and washable.

You do have lots of selections to choose from. Some people use canvas, denim, or muslin for interfacing.

Bucket Hat Interfacing

For this style of hat, you want the brim to have some shape but also some flexibility. That means you may have to use a medium weight interfacing and sometimes, the interfacing for dresses and blouses will work.

It can be fusible as well. The key is to make sure the hat retains its shape while still being comfortable. Some sewers have used Pellon #808 with success but again, the interfacing you will use has to weigh either the same as the hat fabric or less than that weight.

In other words, you have lots of freedom to choose which fabric to use as interfacing for a bucket hat. Then you can either use a sew-in interface type or a fusible type. Whatever works for your sewing project and the hat’s purpose.

Interfacing for a Sun Hat


Denim, canvas, muslin, are some of the more popular choices for interfacing. These fabrics work well if you will want to wash the hat someday. But you have lots of options to choose from.

There is the Pellon option as well as the Craft bond and the Decor bond variety. The key to making a good sun hat is to use the right interfacing that will work for the purpose of the hat. If you want some flex to the brim, don't use stiff interfacing.

Some sun hats get tossed around, crushed, or placed in difficult locations so you want an interface material that handles that type of treatment.

Fusible Hat Interfacing

This is a handy material that lets you use your iron over your sewing ability to make sure the interface stays where you want it. This option is very easy to use and can be found in both woven and non-woven varieties.

When looking to use this type of material always double-check the weight before you buy. It won’t work if the fusible interfacing is too heavy for the exterior fabric. What is good about interfacing is that you can buy this type almost anywhere.

Your hardest decision will be where you buy it from and how much you will spend. Quiltsmart may be a good brand if you do not like to use Pellon options.

Stiff Interfacing For Hats


If you are looking for a brand then Timtex may be the one that has the stiffest interfacing for hats. The key, as has been mentioned frequently here and all over the internet, is to not have the stiff interfacing heavier than the exterior fabric.

A little bit lighter would be ideal instead of having it at the same weight. If you are looking for a specific type of interfacing, the knit type is the one with the least amount of stiffness. The non-woven variety is the one to use as it has the stiffest interfacing of all the types available.

But again, which variety you use depends on how stiff you want that hat brim. In case you are out of interfacing and don't have time to buy more, check our interfacing substitute post for alternatives.

Some Final Words

Finding interfacing for hats will be one of the easier steps in your hat sewing project. There are countless options available and you have to know how stiff or flexible you want that hat or brim to be to find the right interfacing.

Make sure to have several styles and weights on hand. Then take a small piece of exterior fabric and see which one works best for your hat style. One of the harder decisions in hat interfacing will be to go with fusible or sew-in styles. Both are good.

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