Fleece Hat with Ear Flaps Pattern (free) with tutorial

This double lined fleece hat is cute, warm and will work with most of the Halloween Hat packs! I love this fleece hat tutorial. It comes with a free pattern. It looks so warm and cozy too! Easy sew and sizes child to adult! Love this fleece sewing project. Double the warmth of the Original fleece fun hat, this fleece hat with ear flaps pattern comes over the ears to make it perfect for cold weather.  Sizes child to adult for all to enjoy! There is a baby version here.

For this project you will need:

1/2 yard of fleece in 1 or two colors

Sewing Essentials (scissors, pins, etc.)

Fleece Fun’s free pdf pattern available aby filing out the form here.


Fleece Hat with Ear Flaps Pattern (free) with Tutorial (Video)

Fleece Hat with Ear Flaps Pattern (free) with Tutorial (Written)

Step 1 – Assemble the pattern and cut out pieces


You will need to assemble the free pattern.  For instructions on how to assemble the sewing pattern click here.

Fleece Hat with Ear Flaps PatternThe pattern doubles as the front and back pieces.
For the hat you will need cut out
1 of the exterior/ lining front from colors a and b

Fleece Hat with Ear Flaps Pattern
1 of the exterior/ lining back from colors a and b

Fleece Hat with Ear Flaps PatternFleece Hat with Ear Flaps Pattern
You have the option of making the hat reversible by making both the exterior and lining out of fleece.
You can also make the lining out of jersey knit.

Step 2 – Begin to Sew

Fleece Hat with Ear Flaps Pattern

With right sides together sew the front of the exterior to the back of the exterior (note that the front and the back of the hat are not symmetrical.

Fleece Hat with Ear Flaps Pattern

Use a .5 inch seam allowance sew the side seams together leaving the v open.

Fleece Hat with Ear Flaps Pattern

Repeat with the lining.

Step 3 – Sew the V  shut

Fleece Hat with Ear Flaps Pattern

Then turning the hat, sew the v shut.

Fleece Hat with Ear Flaps Pattern

 (Pinch the v together, right sides of the front together, right sides of the back together, pin, sew together in one continuous .5 inch seam).

Step 4 – Snip the curves and bring it together

Fleece Hat with Ear Flaps Pattern

Cut slits around the top of the curves. of the lining and the exterior.

Fleece Hat with Ear Flaps Pattern

Take the lining and stuff it inside the exterior, so right sides are touching. (Make sure the two front pieces are touching and the two back pieces are touching).

fleece hat with ear flaps free pattern

Fleece Hat with Ear Flaps Pattern

Line up the seams and the bottoms. Pin the bottoms of the lining and the exterior together.

Fleece Hat with Ear Flaps Pattern

Sew all the way around the bottom using a .5 inch seam allowance, leaving a 3 inch gap for turning in the back.

Fleece Hat with Ear Flaps Pattern

Cut slits in curves (taking care not to cut through seam allowance) and trim down places where fabric is bulky (like the ends of the straps). 

Fleece Hat with Ear Flaps Pattern

Turn right side out using the opening at the bottom back (work with a it a little as it is a squeeze).

Step 5 –Flip right side out

Fleece Hat with Ear Flaps Pattern

Once turned right side out, stuff the lining of the hat into place. You can hand sew the gap shut or tuck in the raw edge and sew shut by machine. 

Fleece Hat with Ear Flaps Pattern

Top stitch all the way around the base of hat .25 away from the edge (this is optional, but highly recommended). You’re finished with fleece hat with ear flaps free pattern.

Get the Free Sewing Pattern Below:

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You Might also like these free Fleece Hat Patterns:

Additional Fleece Sewing Projects:

I love this fleece hat tutorial. It comes with a free pattern. It looks so warm and cozy too! Easy sew and sizes child to adult! Love this fleece sewing project.


  1. Angel, I was not able to copy the directions for the fleece mittens for children . I kept getting all the pop-ups.WHAT’s THE DEAL??? Mare

    1. Hi Angel, I’m not able to get the ear flap pattern, I get the basic in it’s place. Am I not finding the right link to follow?? I love the ladies comment from FL about the cotton weight for warmer climates I would so make some for our local hospitals. Thanks for your cute easy ideas😁

  2. Absolutely adorable hat…just you Angel..I’m going to make some for the grandkids and the adults….excellent tutorial…fun website..thank you so much..Have a Blessed Day..Gail K.

  3. I live in Florida, so I have no need of fleece’s warmth – this year. Last year, when I lost my hair to chemo, my head was frequently cold. Now I have my chemo curls and no need for heat again, but I do wear hearing aids and drive a very fast golf cart on our adult community streets. I can see this darling cap sewn in some cute novelty quilting weight cottons and worn to keep the wind from blowing off my tiny hearing aids! That’s just for me. For others, I’d love to make some of soft knits for others undergoing the trauma of hair loss and chemo, because its a double whammy painful thing. A comfort cap is so necessary on so many levels. Thank you for your generosity in providing the patterns for both children and adults. Kids feel the pain of hair loss, too.

    Oh, you should know that there are ads between your pictures that all say “Download Here” on big green buttons, and they have nothing to do with your sweet cap. That may cause some problems for others.

  4. I cannot find the pattern to print it says “Get the free pattern below” but there is nothing below the writing.

  5. I bought two fleece blankets for $2.50 at Walmart and cut 7 adult sized hats. These are fun to make. I did plaid and solid reversible. Some I made with no earflaps and just rolled the edge up. Thanks for sharing.

  6. Hi! I was tryin to suscribe me to get the hat with ears flaps but there is a “Recaptcha not valid (0.1)” warning and I couldn’t do it. Please help me, I want the pattern

  7. i love your patterns! I made four of the hats and took to church and they fit 4 children from one family, they were thrilled! Thanks so much, just wanted you to know you are making a difference in Peoples lives, and that of my Grandson!

  8. Hi, just wondering how your sizing works for your hats….do your measurements (shown on the pattern pieces) include the seam allowances? Or do I need to allow for the seam allowance when picking a size?
    Thanks much!

  9. Cannot open the zipped file as you require WinZip, I do not have or wish to purchase WinZip,( too costly). I do have a different PDF program but your site does not give me the option to use anything but WinZip. As I do crafts, I have purchased many, many zipped designs from many different web sites and have never been required to purchase WinZip to unzip them. Very disappointing.

    1. Hi Judi,
      You can absolutely unzip files without WinZip I’m not sure why you think it’s a special requirement of my files. My files are zipped using Windows 10 and not some special software. This sound like a technical problem on your end. And maybe a little bit of googling will provide a solution.

  10. I am also receiving the regular hat pattern in place of the pattern with ear flaps. Could you try sending it again, please?

  11. Thank you for sharing these patterns and your videos. I am new to sewing. I already made 8 basic fleece hats. Fleece from Walmart. Trying the ear warmer and having trouble understanding button holes. So, now I am going to try your other hat pattern. This is already going to be a hit with my coworkers since we work in a cold environment.

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