Solid-Color Polarfleece Hat


Developed in the 1970s as a synthetic alternative to wool, Polarfleece is an excellent winter fabric because it's soft, lightweight, durable, and machine-washable. And although it traps heat just as efficiently as wool, its stretchy fibers don't shrink or absorb water. These Polarfleece hats are relatively easy to construct and make wonderful holiday gifts.

Average Head-Size Chart:

Newborn (6 Months and Younger)

Circumference: 14 to 17 inches

Crown: 8 to 10 inches

Infant (6 to 12 Months)

Circumference: 16 to 19 inches

Crown: 11 to 12 inches

Child (1 to 3 Years)

Circumference: 18 to 20 inches

Crown: 11 to 12 inches

Child (3 Years and Older)

Circumference: 20 to 22 inches

Crown: 13 to 14 inches

Adult Woman

Circumference: 21 to 23 1/2 inches

Crown: 13 to 15 inches

Adult Man

Circumference: 22 to 24 1/2 inches

Crown: 14 to 16 inches

Try another of our Polarfleece hat projects: Horizontal-Stripe, Vertical-Stripe, Crown.

What You'll Need


  • Soft tape measure
  • Polarfleece fabric
  • Scissors
  • Pins
  • Tailor's chalk
  • Strong matching thread
  • Thread
  • Small pom-poms (optional)


  1. You'll need one panel of fabric to make this hat. To determine the width of the fabric, measure the circumference of your head (including your ears), or use our size chart, adding a 1/4 inch on each side for seam allowance. The length for an adult hat should be about 13 inches; for a child's hat, about 10 inches. Cut out the panel of fabric.

  2. With right sides facing in, sew the long ends, forming a tube. Trim seam allowance closely. If you wish to press open any remaining seam, use your fingers; do not use an iron because the fabric could melt.

  3. To make a cuff, fold up bottom edge of fabric about 3 inches, then fold in another 1/4 inch for seam. Sew hem close to the turned edge.

  4. Sew along the top of the hat, leaving a 1/4-inch seam allowance. Trim seam. Turn hat right-side out.

  5. You can finish off the top of the hat with or without ears. For a hat with ears: Pinch corners into a fold, with the opening of each fold, facing front. Using matching thread, tightly tie off each folded corner about 1 1/2 inches down. Secure with 3 or 4 hand stitches through each ear. For a hat without ears: Join the two corners of the top of the hat together with a single stitch. Using strong thread, bring the needle through the inside of the hat at one corner and through the top of the other corner. Pull thread tight so the corners meet at the center. Tie off the thread inside hat.

  6. For a large pom-pom, cut a strip of fleece 24 inches in length (or 9 to 12 inches for a smaller pom-pom) and as wide as you would like the pom-pom (4 inches is a good width for an adult hat). Fold the strip in half widthwise.

  7. Lightly draw a line down the center of the fabric lengthwise. Cut fringes to the left and right of the line, leaving about 1/4 inch uncut in the center. The fringes can be as narrow or as wide as you like. Roll up strip of fabric.

  8. Using upholstery thread, bring the needle through the core of the pom-pom, and wrap the thread tightly around the center a few times. Bring needle through the core again, and tie a tight knot. Use the excess thread to sew the pom-pom to the top, or the edges, of the hat.

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