How to Sew a Fleece Hat

From LoveToKnow Crafts

Learning how to sew a fleece hat is a good starter project. Most projects range from easy to intermediate in skill level, with a lot of room for creativity. Start with a single seam and work your way up to adding shapes, unique color combinations, and embellishments.

Fleece hats are simple to make.

The Qualities of Fleece

First appearing in 1979, polar fleece is a synthetic fabric created to mimic the qualities of wool -- minus a few of its characteristics.

Similar to wool, fleece is soft to touch, a good insulator of heat, and ideal for outerwear. However, unlike wool, it's a rugged material that is able to withstand wear and tear as well as machine-washing. Fleece also weighs less than wool, is non-itchy, and does not lose its shape.

It’s also known as microfleece and micrafleece.

Sewing with Fleece

Fleece sewing projects are generally simple. Easy-to-follow instructions can show you how to sew a fleece hat, a scarf, or pair of mittens. Thick and durable, fleece is also a very forgiving fabric that doesn't fray its edges.

Because of the thickness of fleece, you'll want to use:

A needle that matches the weight of the fabric
A good pair of scissors, pinking shears or a rotary cutter
100% polyester thread to prevent shredding or breaking

A single seam is all you need for some hats and this can be done by hand if you wish. However, a sewing machine is necessary for projects that require tight stitching.

Learn How to Sew a Fleece Hat

Fleece hats are an insulator, a fashion accessory, and a nice idea for a gift.

To sew a fleece hat, you'll need the sewing supplies noted above, plus:

Fleece fabric: Hats are small, so a yard should be more than enough to practice with and make your hat.
Straight pins: Though fleece is easy to work with, you still need to keep your pieces aligned for sewing.
Soft tape measure: It all starts with proper measurements.
Embellishments: This can be anything you like, from a pom-pom to a fringed tassel.

Sizing Things Up

For any hat, you want accurate measurements. Unlike sweaters or pants, which may be OK if too big, hats need to fit snug on the head. By the same token, they can’t be too tight either or else they’ll pop off.

Fortunately, size charts, like this one provided by Martha Stewart, provide a good starting point for most hats. When you measure, you want to measure the circumference of the head close to the ears.

Keeping Things Straight

As said, you'll want to keep your fabric aligned and in place once you begin sewing. Even for single-seam or low-sew hats, you don’t want your fabric to bunch up -- even in the back of the hat. For hats that use more than one panel, you should pin the entire hat before attempting the first stitch.

A Few Considerations

When working with fleece, remember:

Mind the "nap". The fiber ends of fleece all lie in a particular direction, which should be kept consistent throughout. Thus, when cutting your fabric, be sure that your panels face the same direction. If not, you could end up with odd shading.
Wrong side, right side. Determine which side of the fabric looks best and mark the other side as the inside; this will be the outside while you work (before turning the hat inside out).
Medium-weight fleece. A good fit for hats, this weight of fleece also works well for jackets, mittens, socks, and blankets.

Ideas and Inspiration

As you begin looking at projects, you’ll find that hats invite a lot of creativity. Embellishments, such as pom-poms, animal ears, or appliqués, can produce one-of-a-kind caps, beanies, and berets. For kids especially, fleece hats can be fun projects that are as whimsical as they like.

For a few ideas and inspiration, check out these projects detailing how to sew a fleece hat from scratch:

Martha Stewart: Five versatile styles, including a fun jester hat and vertical-stripe.
Jenny T.'s Simply Sewing Projects: Clear instructions complete with diagrams. In all, 17 steps.
RawrPhore: A DIY project that ends up with a fleece hat with cat ears.
HGTV.com: A fleece hat ready for embellishment(s). Matching scarf part of project.
Happy Together: A hat that can be sewn by hand. Only six steps and less than an hour to make.
FamilyFun: Another low-sew hat, this one is cinched at the top with a decorative cord.
MakingFriends: A low-sew project resulting in a cozy winter hat with fringe top.
Instructables: For when you get confident in the basic design. Add ears, eyes... and a mane.