12 Days of Cuddle® Day 7: Luxe Cuddle® Cat Hat

 Written by Cuddle® Ambassador and Education Manager, Michelle Hall

Making Luxe Cuddle® Cat Hats: A Fun and Stylish Project from Judy Gauthier’s Sew Cuddly

Hi, everyone! I’m Michelle Hall, and I’m thrilled to be here for day 7 of the 12 Days of Cuddle® Holiday Project Series! As the Education Manager for Shannon Fabrics with over 35 years of sewing and quilting experience, I’ve made countless stuffed animals and accessories. Today, I’m excited to share my take on the Luxe Cuddle® Cat Hats from Judy Gauthier’s Sew Cuddly book!

These hats are adorable, cozy, and a perfect way to showcase the luxurious textures of Cuddle® and Luxe Cuddle®. Let’s dive in!

About the Sew Cuddly Book

Written by Judy Gauthier, Sew Cuddly is a fantastic resource for anyone who loves working with plush fabrics. The book offers clear, detailed instructions and step-by-step photos, making every project approachable and fun.

Why I Chose the Cat Hat

My four grandchildren adore Cuddle® fabrics and love snuggling with their cats at home, so I knew this project would be a perfect hit. Whenever a new shipment of Cuddle® fabrics arrives, they can’t wait to request blankets, stuffed animals, and now—Cat Hats! I couldn’t resist creating a personalized version of the hat for each of them. With multiple sizing options in the Cat Hat pattern, it’s a fun project everyone can enjoy!

Materials Needed

• From the Sew Cuddly Book by Judy Gauthier:
  • Cat Hat pattern
• Supplies:
  • Sewing Machine with or without walking foot
  • SCHMETZ 90/14 Jersey or Stretch Needle
  • Mettler Metrosene 50 wt Polyester Thread
  • Silky Poly-Fil® by Fairfield World
  • Clover Flower Head Pins and Wonder Clips®
  • Swedish Tracing Paper
  • Usual sewing supplies
  • Cording for hat strings
• Fabrics:
  • Luxe Cuddle® Snowy Owl Natural
  • Cuddle® 3 Cappuccino for hat lining and inside of the ears

Getting Started

Pattern Preparation:
Consider using Swedish Tracing Paper to trace the pattern in multiple sizes. It’s durable, see-through, and pliable, which makes it perfect for sewing mockups to check sizing. For this project, I wasn’t sure if the Small or Medium size would fit the oldest grandchild, so the tracing paper saved time and fabric.

Checklist for Sewing with Cuddle®

• Use a SCHMETZ size 90 Jersey or Stretch Needle.
• Use a walking foot to help manage the layers.
• Increase stitch length to 4mm.
• Pay attention to the nap when cutting and sewing to ensure all pieces flow in the same direction.
• Control “Cuddle Dust” by shaking cut pieces outside or running them in a dryer on low heat with a damp cloth for 10 minutes.
• Use Wonder Clips® instead of pins for thicker sections like the ears and pom-poms.

Making the Cat Hat

1. Fabric Selection:
   The Luxe Cuddle® texture added personality to the hats. My fashion-forward grandchild even insisted on dark contrasting ears for more impact, which turned out great!
2. Ears and Pom-Poms:
   • Ears: Stuff with Poly-Fil® and trim the seam allowances to reduce bulk. Sew them securely to the Hat Side—these ears aren’t going anywhere, even if tugged!
     
   
    
   • Pom-Poms: Follow Judy’s instructions for hand-sewing the pom-poms. I initially tried a machine basting stitch but found hand stitching worked best for creating round, full pom-poms.
   
   
3. Lining:
   Sewing the Cuddle® 3 lining required some easing due to the curved pieces. Match notches first, then pin from the edges inward. Take your time, and it will come together beautifully!

1. Finishing Touches:
   Stitch the cotton cording to the hat and sew the lining and outer pieces together. I left a slightly larger opening than suggested (2.5–3˝) for easier turning.

Why I Loved This Project

The Cat Hat is a delightful mix of creativity and practicality. It’s warm, stylish, and customizable for any personality or age. Whether you use solid colors or playful prints, the end result is guaranteed to bring smiles.

Get Inspired!

I’d love to see your take on the Cat Hat pattern or other animal hats from the Sew Cuddly book! Share your creations in the “I Love Cuddle® Fabric” Facebook group or Instagram.com/shannonfabrics #SewCuddlySewAlong

Joining Shannon Fabrics as the Education Manager has been an incredible journey. It’s given me the opportunity to teach, work with talented people, and explore the endless possibilities of sewing with Cuddle®.

If you’re interested in learning more about Shannon Fabrics' education programs and Cuddle® Ambassador opportunities, click here or reach out to education@shannonfabrics.com.

Happy sewing and enjoy creating your own Cat Hats! 

Michelle Hall
Education Manager Shannon Fabrics