On a snowy Christmas Eve, the magician Professor Hinkle, Billy De Wolfe, is hired to perform at a school’s party, but the act goes awry and he blames his hat, tossing it aside in a fit of frustration. The tale is told by the narrator Jimmy Durante, whose warm voice guides us through the ensuing mischief and magic. Outside, the children gather to play in the snow and build a snowman, the group debating what to call him before they settle on Frosty the Snowman Jackie Vernon. When a hat lands on Frosty’s head, the snowman comes to life, a moment of wonder that turns into a stubborn contest of will between Frosty and the hat’s true owner.
Professor Hinkle quickly realizes the hat’s powerful trick and sees a golden opportunity to get rich, reclaiming the hat from the children despite their protests. In the meantime, Hinkle’s mischievous rabbit, Hocus Pocus, conspire to switch the magical hat with a Christmas wreath, robbing him of his prize and transferring the magic back to Frosty and the kids. With Frosty revived by the hat’s magic, the party mood shifts to a frantic bid to keep him from melting as the temperature climbs.
To save Frosty, the children decide to move him toward the North Pole, proposing a train journey. They parade through town toward the station, a moment that astonishes several townsfolk and a traffic cop as Frosty glides along in his own world of wonder. Lacking train tickets, Frosty, Hocus Pocus, and Karen June Foray secretly board a freight train’s refrigerator car, while Professor Hinkle discovers their switch and follows, clinging to the caboose below.
As the northbound journey continues, Karen begins to suffer from hypothermia, and Frosty realizes they must find warmth and help quickly. The trio disembarks at a stop to seek shelter, and Frosty and Hocus call upon forest animals to erect a campfire for Karen. Yet the fire isn’t enough to keep the chill at bay, so Frosty decides to seek out Santa Claus, hoping the jolly visitor can save Karen and guide them to the North Pole. Santa Claus arrives with aid in mind, and the children’s hopes rise again as they press on toward safety. Paul Frees lends his voice to Santa, bringing a calm assurance to the journey.
Meanwhile, Professor Hinkle closes in, intercepting Karen and Frosty at a greenhouse and locking them inside. By the time Santa and Hocus reach the greenhouse, Frosty has begun to melt, leaving Karen and Frosty distraught. Santa consoles Karen, explaining that Frosty is made of magical Christmas snow and will return every winter. He then opens the door and a wintry wind swirls in to remake Frosty, the magic snow reviving him anew. Hinkle arrives again, demanding the hat, but Santa offers him a deal: no more gifts for him unless he apologizes, and then Hinkle sets out to write his apologies, hopeful for a new hat in the future.
With apologies on the page, Frosty is revived once more, and Santa escorts him toward the North Pole, dropping Karen back at her home along the way. Frosty leads the town in a festive parade, joined by Hocus Pocus, the narrator, a surprised traffic cop, and the rest of the community, now including a redeemed Hinkle sporting a fresh hat. The parade culminates as Frosty climbs onto Santa’s sleigh and flies away to the North Pole, with the snowman playfully altering the final lyric of the season’s song to announce his return. > I’ll be back on Christmas Day!