DIY Baby Bear Hat (Free Pattern Inside)

Are you ready to create a cute and cozy DIY baby hat for your little one? This step-by-step sewing tutorial will guide you through the process of making an adorable baby hat with bear ears, which is why I call it “Baby Bear Hat”. 

This project is very easy to make and comes with a free downloadable pattern so you can print at home and get started with sewing right away!

Materials Needed:

• Free Baby Hat Pattern (Download Link)

• Soft knit fabric. You can use 2 types of fabric for the exterior fabric and lining

• Matching Thread

• Sewing Machine

• Scissors

• Pins

Step-by-Step Instructions:

Step 1. Print and cut out paper pattern:

Begin by downloading the free baby hat pattern and printing it at 100% scale. Cut out the paper pattern. This pattern includes a seam allowance of ¼” inch.

Step 2. Cut fabric:

Using the paper pattern as a guide, cut out the fabric pieces for the hat. You will need 4 hat pieces, 4 ear pieces, and 1 hat band. I used the same fabric for exterior and lining of the hat, but you can opt for 2 contrasting fabrics for them.

Step 3. Sew hat pieces:

Fold each hat piece in half aligning the dart. With right sides together, sew the hat pieces to close the dart using a straight or zigzag stitch. Use a walking foot if sewing with a straight stitch to prevent stretching out the fabric. Repeat this step for all four hat pieces.

Step 4. Sew ear pieces:

Pair up 2 ear pieces with right sides together and sew along the edges using a zigzag or straight stitch. Turn the ear pieces right side out. 

At this stage I also overlapped the ears a bit in the center by ¼ to ½ in to create a fold. I just pined it in place but feel free to use staystitch instead for extra security.

Step 5. Attach ears to hat:

Position the ear pieces onto one of the exterior hat pieces, aligning them as desired. 

Then place the remaining hat piece on top, right sides facing each other. Sew around the outer edge of the hat using a zigzag or stretch stitch to sew the two hat pieces together and secure the ears in place.

Repeat this step for the hat lining fabric, excluding the ears. And now you should have 2 hats: one exterior hat with ears and one hat lining without ears.

Step 6. Make the hat band:

Fold the hat band piece in half lengthwise and sew along the raw edge using a stretch stitch. Open up the band and fold it lengthwise to create a double-layered band.

Step 7. Assemble the hat:

Insert the hat (with ears) into the hat lining, ensuring the wrong sides are facing each other.

Place the folded hat band around the bottom edge of the hat, aligning the raw edges. Sew around the circumference of the hat using a stretch stitch or serger.

Step 8. Finish the hat and enjoy

Once sewn, flip the hat right side out to reveal the finished product. The bear ears should be pointing up now. 

The stitched or serged edge should be visible on the exterior of the hat and this is intentional. When we fold the band up, it naturally conceals the seam, and is more comfortable for the baby to wear it. 

If you prefer the seam to be inside, simply switch the order when you put the two hat pieces together (tuck the hat lining piece inside the hat exterior piece)

Here’s what the finished baby hat with bear ears look like:

Summary

Thanks for making it till the end! This sewing project is easy but very rewarding and only takes a couple hours to make.

Whether you’re making a hat for your little ones or as a sweet baby gift for a friend or family member, this DIY baby bear hat will be a great project to try.

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