Halloween Hat Pack – free fleece animal hat patterns

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These free fleece animal hat patterns have something for everyone! I love these cute (and warm) fleece hats.  I bet my kid would wear it not just on Halloween, but all winter long!  And there's a video tutorial  - just what I need.The variations includes a dragon/ dinosaur hat, Viking hat, bear ears, cat ears, pumpkin, and apple. Comes in sizes Baby to adult. Perfect for Halloween and beyond.
Materials you will need:
1/3 yard fleece
1/8 yard contrasting materials for pieces (might need 2 colors)
Assembled printed pattern

The Measurements are for the circumference of the head.  So the measurement you would get if you too a measuring tape and wrapped in around a person’s head.  Please not that fleece can have varying amounts of stretch to it.

Small – 16 inches or 40.64

Large – 17 inches or 43.18 cm

Small – 17.5 inches or 44.45

Large – 19 inches or 48.26 cm

Small 20 inches or 50.8 cm

Medium 22 inches or 55.88

Download the free pattern, tutorial below!

You can get a free copy of Adobe reader here– it is the ONLY reader I recommend. By downloading  you are agreeing to pattern terms of use. Click the picture of the pattern envelope to download the .pdf !

Video tutorial here, written below:


Cat Hat and Bear Hat

These two pattern may look different but assembly is mostly the same.

1- Assemble and cut out the Pattern

You can find instructions on how to assemble the pattern here.

Cut out both of the pattern pieces for the desired hat.  For contrast I recommend cutting out the ear interior (the smaller piece) with a contrasting fabric. Plus two of the basic hat pattern.For bear ears: If you want the ear to have a dent make the top and bottom of the line on the interior ear pieces on the right side of the fabric.

2 – Begin to pin and sew the ears

This is the trickiest part of the pattern.  Taking and exterior and interior ear piece, put right sides together and line up the bottoms of the pieces.    The exterior is larger than the interior so your ear will have a nice outline.  Line up the exterior edges of the piece and pin (this will cause the back to bubble). I like to use a lot of pins to get this right. For a baby hat use a .5 inch seam, for a child or adult hat use a .25 inch seam.Turn right side out.For Bear ear: Sew top stitch seam on ear if desired. For Cat Ear: Turn each bottom corner into center of ear, pin and baste stitch down.

3 – Place the ears and make the hat.

Place and pin the ears where you would like them to be on the hat (a third of the way down seams to work well).  You want the tops of the ears facing in, sitting on the right side of the fabric, you will then place the other half of the hat (right side down) on top.Using a 1/2 inch seam allowance, sew each side of the hat (the long curved side to the point before it dips into a “V”.  Be sure to leave the bottom (the brim) open. Now that you’ve sewn the sides of the hat it’s time to close the top.  Fold the hat in half so the seams you just sewed are touching.  Pin the “v” on each side closed.  Sew one seam along the top of the hat closing the v on both sides. (This will make a rounded top.)Turn the brim edge under 1 inch (or more/less if you like) pin and sew a zig-zag stitch over the edge of the fabric.  Snip any loose threads and turn right side out.
Tada!  Your hat is finished.Tip: Because of the layers, sew slowly over the sections with the ears – it will keep the stitches more even.

Dragon/ Dinosaur Hat and Viking Hat

What little boy wouldn’t want to run around in this hat all winter?

These two hats are similar in their assembly.

1 – Cut out pattern pieces and pin

You can find instructions on how to assemble the pattern here.Cut out both of the pattern pieces for the desired hat, plus 2 of the basic hat pattern.Dragon hat:  To get the right amount of Dragon “plates” for your hat, take the pattern pieces and set them on top of the hat pattern to make sure the amount you need is correct.Viking hat you just need two of each pattern piece.

2 – Sew the Horns

Sew each horn together.  For Baby hats use a .5 inch seam.  For children and adult hats use a .25 inch seam.  Sew two sides of the horn, leaving the straight side open for turning.Trim with scissors close to the top point of the horn (this will give it a nice point when turned).  Turn horn right side out, pushing the fabric so you will have a nice point at the top of your horn.Stuff each horn with a little bit of poly fill or fleece scraps, making sure that there is a finger width’s of space at the bottom with no filling.
(Optional for Dragon hat – but a must for the Viking)

3 – Finish Assembling the Hat

Place horns on right side of fabric as pictured.  Pin in place. Then baste in place (this will make it easier to sew together.) Place other side of hat right side facing in on top, sandwiching the horns.tip: Be sure the horns are facing inward.  For the Dragon Plates be sure that you leave a .5 space before and after the “v” to make sewing the hat shut easier.Using a 1/2 inch seam allowance sew each side of the hat (the long curved side to the point before it dips into a “V”.)  Be sure to leave the bottom (the brim) open.Now that you’ve sewn the sides of the hat it’s time to close the top.  Fold the hat in half so the seams you just sewed are touching.  Pin the “v” on each side closed.  Sew one seam along the top of the hat closing the “v” on both sides. (This will make a rounded top.)Turn the brim edge under 1 inch (or more/less if you like) pin and sew a zig-zag stitch over the edge of the fabric.  Snip any loose threads and turn right side out.
Tada!  Your hat is finished.

Pumpkin and Apple Hats

So cute, you could just eat them up!  These hats are very similar in their design and assembly.

Tip: Because of the multiple layers sew slowly over the sections with the horns – it will keep the stitches more even.

1- Cut out the pattern

You can find instructions on how to assemble the pattern here.Cut out both of the pattern pieces for the desired hat.   You will need two of the stem and only one of each leaf, plus the 2 cut outs of the basic hat.

2- Pin and Sew

With right side together sew the stem, leaving the bottom open for turning. For baby and child use a .5 seam allowance.  For adult a .25.Trim top and turn right side out.Then stuff stem using poly fill or fleece scraps leaving a finger’s width at the bottom not stuffed.

3 – Finishing the Hat

Using a 1/2 inch seam allowance, sew each side of the hat (the long curved side to the point before it dips into a “V”.)  Be sure to leave the bottom (the brim) open.Now that you’ve sewn the sides of the hat it’s time to close the top.
But first you are going to place the stem and the leaves (facing down into the hat – in between the right sides.).  This way when you sew the “v” shut you will also sew on the stem and leaves.  Fold the hat in half so the seams you just sewed are touching.  Pin the “v” on each side closed.  Sew one seam along the top of the hat closing the “v” on both sides. (This will make a rounded top.)

Angel Hickman Peterson

Angel Hickman Peterson

Creator, Editor and Author at Fleece Fun
Angel has a bachelor’s degree in Film Studies from the University of Utah, with a professional background is in film, television, radio and ad production. Angel currently divides her time between her small production company Angel Dawn Productions, her online sewing and crafting blog www.FleeceFun.com, her two little girls, baby boy, husband and on very good days also manages to get the dishes done.
Angel Hickman Peterson
Angel Hickman Peterson

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  1. 1

    Koala says

    Vey nice patterns, I can’t wait to try this and the patten for the cape ^_^ Great job, as expected. Thank you so much.


  2. 2

    Suzy Ott says

    I LOVE ALL of your patterns!!Thank you sooooo much for the free patterns!!I really appreciate you doing this!! My husband was just laid off and i am 9 months pregnant and i am making stuff for my baby and this helps us out sooooo much!!! THANK YOU AGAIN AND GOD BLESS YOU AND YOUR FAMILY 😀

  3. 3


    Awesome patterns. Thank you SO much for making these available for free. I was going to purchase a car seat canopy cover/replacement car seat padding and it was going to be $30 JUST to ship it… It is supposed to be a free deal thing. We had a boy first and now we’re having a girl. I figured this would be a great way to personalize the old teeny car seat for a new arrival! P.S Would you, Could you… make a pattern for a car seat padding replacement? heh.

    • 4


      Hi Kristi!
      Unfortunately I won’t be making a car seat padding replacement anytime soon for 2 reasons: 1 – there are so many baby car seat styles that it would be impossible to make one that would fit. 2 – Car Seat Manufacturers are against home made padding covers as they can interfere with the mechanics of a car seat and put a child at risk.
      Fortunately the baby car seat canopy hides a used or well loved car seat. =)

  4. 5

    Morgan says

    Love love love these hats! And so do my kids… Made the Viking and dinosaur hats tonight. I had a really hard time getting my foot to go over multiple layers of fleece. Once it got started it would feed through pretty good, but at the next horn or seam and it wouldn’t move. Any suggestions?

    • 6


      Hi Morgan!
      A couple of things you can try when sewing through lots of layers. Be sure that you have that finger width of “no batting” at the bottom of the horn so you’re not trying to sew through four layers of fleece and batting. You may want to try sewing it with a slightly larger/ sturdier needle. This can make a big difference when it comes to heavy layers.
      Hope that helps!
      – Angel

    • 8


      Hi Kathy!
      I think if you used the cat ears they might work for horse ears. Maybe try putting on the mane, like the dragon plates and then put the ears on when you sew the v shut. Good luck with your project!
      – Angel

  5. 9

    Jane says

    First of I LOVE everything! I was wondering if a child that was 5t would that be a size small child’s pattern?

  6. 12

    Tammi says

    Thanks so much! These were super fun to make and the grand-kids love them. Instructions were great. Going to use my scraps to make hats for our local homeless shelter. Thanks again!

  7. 16

    Yanna says


    I have been recently visited your website and I am surprised. I really didn’t know how many things except of throws can be made with fleece. I have bought fleece and made pj for my kids. Now straight away for the hat pack 1 and 2.

    Love your videos. Very helpful instructions. Your work is awesome.

    Thanks so much.

  8. 17

    Kate says

    I love these patterns, thank you so much for sharing them. A quick question I don’t quite understand these instructions for making the crease in the bear ear? “make the top and bottom of the line on the interior ear pieces on the right side of the fabric.” Am I meant to cut here or sew along the line or join the top and bottom together? I am a novice at sewing but would love to get the crease. :) thanks again.

    • 18


      All you need to do is topstitch (stitch on the fabric – no seam involved) down the middle of the ear to make the crease. This is purely a decorative stitch – the ear will function fine whether you do this stitch or not.
      – Angel

      • 19

        Kate says

        Thank you, that helps me a lot. My little girl has just asked me for a mouse hat I am looking forward to getting started now.

  9. 20

    AF says

    Terrific patterns! I’ve on my 5th hat now and LOVE them! We’re into hippos here at the present moment so I’ve been making the bear ears and sewing them down more like a hippo ear then adding eyes, nose, teeth etc to make them really look hippo – thanks for the easy to read directions!

  10. 21

    Sara says

    I’ve just made one of your hats for a 10 year old boy, but I doubt it’s going to fit him… I took the teen/adult’s small size… As it’s for a gift I can’t measure the head, what do you recommend?

    Anyway, I love your patterns and work instructions, they are really easy to follow.

    • 22


      HI Sara,
      Boys heads are closer to being full grown – bet you the adult medium will fit him great. It’s hard to give “hard rules” for fitting as it can vary so much.
      – Angel

  11. 23

    Deborah says

    Thank you for this pattern. I just made some of them to use for lamb costumes in our nativity this year. They are adorable!

  12. 24


    When you fold the sides together, I’m confused… do you sew straight down the V or across the whole top section of the hat? Could you post a picture showing exactly where to sew?

    I feel like an idiot since everyone else says how simple these are to make, and I can’t figure it out. :)

  13. 26

    Courtney says

    I want to print out the pattern to make a hat for my baby but all the infant patterns only have the small parts like the parts to make the eyes for the frog or the horn for the viking but not the actual hat part of the pattern…

    • 27


      I am not sure what the issue is. I’ve checked the patterns and the hat part is part of the file… try dumping your internet cache and reloading to see if that fixes it.

  14. 28


    I’m sorry to bother you. I love your patterns though I’m not a sewer yet. I basically put patterns on a flashdrive to have for when I get my “Round Toit” Are we not allowed to copy the pattern? I want to follow your rules because it is generous of you to give of your gifted talent. I only want the pattern, not to print the whole download. I have to go to another room for printing so I couldn’t just print all of it anyway…plus I do not know very much about computers to know what to do. I am really gratefull you have put the pictures of patterns with the writeup for some of the projects . May I have just the pattern pieces for the lovely tiny top hat and tricone hat? The downloads all say “SECURED” which I’ve found means no transfer to a Word page. If I cannot have them , please just say so and I’ll try to forget the lovely hats.
    Thank you,

    • 29


      Hi Janet,
      You are welcome to store the digital file on your computer and or Flashdrive for personal use. You should be able to print the pdf file from it. As for giving you another version of the pattern – I can’t offer that, but you should be able to take your digital copy print from that. =)

  15. 30

    shelly says

    hey , how can I make sure that my patterns that I take printout are of the right side, actually our printer has many options like, u want stretched size, or actual size, in portrait mode or landscape mode, wat shld I choose, plz help

    • 31


      They should print at actual size, in portrait. Basically I’ve tried to lay them out so you don’t have to make any adjustments to your printer – you just print. =)

  16. 32

    R says

    I made a cow hat. I modified the Viking hat, adding ears below (sew together a brown Cat Outer Ear to a pink Cat Outer Ear, turn inside out, and fold 2/3 along to make a cow ear). The recipient was absolutely delighted!

  17. 33

    Lizzy H says

    Just Wondering, Im just learning to sew and I wanted to make these hat but not use fleece. Do they still hold up fairly well? :) thanks so much your videos have helped me TONS :-)

  18. 34

    Johnny P. says

    Hey Angel, Thank you so much for this tutorial, love it. I was wondering what are the vertical lines at the bottom for, if you don’t mind me asking. Thank you and keep up the good job.

  19. 40

    Anna says

    This is sooooo cute! I sewed the bunny hat and the bear hat and they are adorable!! Can I make a unicorn hat the same way?
    Thanks a bunch,

  20. 42

    Stacy says

    Thanks for the free patterns – these are fabulous! I made the Viking hat and used yarn to make braids for my daughter to go as a Viking for Halloween! Worked beautifully!

  21. 43

    Sarah says

    I love your patterns and can’t wait to make my baby a pumpkin hat! I read your terms of use but want to be absolutely certain that I am allowed to sell items that I personally make using your patterns, as long as I give you pattern credit. Is this accurate? Thank you so much for your wonderful patterns!

  22. 45

    Cynthia Elliott says

    Thank you SO much for this pattern. I don’t really sew, but I am using a modified version of your pattern to make the head of a Hobbes costume for my son and I to be Calvin and Hobbes at Halloween. It is coming out great! The video showed me how to do the ‘V’ at the top which I wasn’t really understanding from the written instructions. You also did a great job explaining how to get so many layers through the machine. :-)

  23. 46


    Sew easy and SEW CUTE! I started with the cat but I have the Dino cut out too one for Grand daughter and one for Grandson and now I know what to do with all the scraps of fleece! THANK YOU SEW MUCH!

  24. 47

    BEVERLY says


  25. 49

    Adi says

    So cute!
    Does it make sense that my 3 year old has a 51 cm head? He’s quite a small child… Maybe I’m measuring wrong?

  26. 50

    Dew says

    Drat!! Trying SO hard to open the hat pattern b/c my friend in sewing class whipped up the CUTEST purple kitty hat in about an hour the other night, but McAfee Web Gateway is denying Google Ad Services, saying it’s a conduit for malicious downloads. Any thoughts on how to open? (Note that I’ve been able to open/download your suuuuuuper cute boutique pants with no problem, but there was an envelope pic there rather than a green Download bar….)

  27. 53

    Melissa says

    Thank you so much for your wonderful tutorials! I just started sewing this week and made your fleece pants and the dragon hat today for my little guy. They turned out really good which is surprising for my beginner status. Excited to go through and try more! And yes I did notice the pants run small. I made the 3-4T for my little guy who wears 2T and they were still a little snug around the thighs. I know i didn’t get as close to the edge on the seam as i should have though. Thank you so much!!

  28. 54

    Ella D says

    Hi, thanks so much for these patterns, I’m having loads of fun with them. I just thought I’d let you know that the small adult hat pattern came up too small for my 6yo son. This is NOT a complaint! I should have measured properly. I just thought you would like to know.

  29. 58

    Anna says

    Thank you for the free pattern and tutorial! I just made a monkey hat using your Halloween Pack, and it looks great (even though I am a sewing novice.) Thanks again.

  30. 59

    Leslie says

    Hi! I found this on pinterest. Thank you so much for the free pattern! I had a lot of fun and it was super easy! Thanks again!

  31. 60


    Thank you soooo much Angel. I am 64 yrs young and I have just gotten back into sewing. I admit I’ve forgotten just about everything and these new machines are so incredible. I was so thrilled to see some patterns I can actually understand lol. I have a new grandson and all these patterns are going to be fun and get my confidence in sewing back.

    It is very nice of you to let people have these patterns for free, your name fits you. :)

    Grandma Jo (Joanne)

  32. 62

    Oriana says

    Awesome!! Hi, i’m from Brazil and I loved your blog, thank you for sharing your technics, you are the best =]

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