BERNINA Corporate Blog -Hey, everyone! Winter is slowly coming for half of the world, and the leaves are crunching underfoot. Maybe you already experienced the first snow of the season? To keep the wind from getting too chilly around the ears, let’s sew a colorful kids’ hat together – either a unicorn or dino look in wool felt (or fleece for a vegan option). I dare say these adorable hats will put an end to those morning hat debates!
Sewing Tutorial and Free Pattern for a Warm Kids’ Hat in Unicorn or Dino Style
I’m Stephi from Frollein Tausendschön, and I love all things sewing, embroidery, and crafting. Feel free to visit me on Instagram!
A quick note: I’ve split the tutorial into two parts to keep it clear. Today, in Part 1, we’ll sew the unicorn hat together. Tomorrows Part 2 will cover only the details specific to the dino version, as the base hat is sewn the same way. You’ll find both patterns available for download at the end of each post.
I’m using my BERNINA 570 QE (NEW) for these hats. For appliqué, I love using the Appliqué Foot #23, which makes clean appliqué easy.
Materials for Sewing a Kids’ Hat
- 40 cm wool felt or fleece
- 40 cm jersey fabric
- Approx. 50 cm of cord
- Sewing thread in various colors for appliqué and hat base
- Fabric scraps for appliqué
- A bit of stuffing
- Jersey scraps for the unicorn mane
- Embroidery film and a fabric marker
- Fusible webbing (Vliesofix)
Please note: The fabric amount depends on the hat size you choose. My measurements are for a hat with a 51 cm head circumference.
Sewing a Colorful Kids’ Hat – Preparations
Preparing the Pattern
Download the pattern (which you can find at the end of this post) to your device and print it at 100% without adjusting the page size. Check the correct size using the control box on the pattern. Printing directly from a browser may cause size differences or misalignments.
Then, assemble the printed pattern pieces.
Faces, ears, and similar elements come in two sizes. Choose whichever size best suits the hat size you selected.
Cutting Out the Unicorn Hat
- 1x outer fabric on fold
- 1x lining fabric on fold
- 4x ears from outer fabric (try different colors for outer and inner ear)
- 2x horn from outer fabric
Seam allowance is included and is 1 cm unless otherwise specified. As both wool felt and jersey don’t fray, finishing the edges isn’t necessary.
Cutting the Mane for the Unicorn
For the unicorn mane, cut several strips of jersey fabric in various colors. Cut them into strips 2 cm wide and 15 cm long.
Now stretch each strip so they curl up slightly – now you have your jersey noodles for the unicorn mane.
Sewing Tutorial
Let’s begin by sewing the kids’ hat from wool felt.
Since these fabrics are a bit stretchy, I sew with an elastic stitch like a triple straight stitch or a zigzag. For jersey, definitely use an elastic stitch, while the outer fabric can be sewn with a straight stitch if preferred. Set the stitch length to 3.7 or higher to ensure even fabric feeding. My BERNINA 570 QE has built-in fabric feeding; if your machine doesn’t, consider using the Walking Foot #50 for easy handling of wool fabrics.
Ears, Spikes, and Horn
The unicorn ears and horn, as well as the dino spikes, are made similarly.
First, take the cut pieces and place them right sides together so the nice fabric sides face each other.
Pin the pieces with clips or pins, leaving the bottom edge open for turning later.
Now sew ears, horn, or spikes with a 1 cm seam allowance, securing the stitch at the start and end. Trim the seam allowance by half.
After trimming, turn the pieces right side out and shape them gently with a seam-turning tool or scissors.
Stuff the unicorn horn with a little filling to give it a nice three-dimensional look and good structure.
Attaching Unicorn Ears
Now let’s add the ears. Take the outer hat piece and the prepared ears.
The hat has V-shaped cuts at the top where the ears will be placed. First, find the middle of one side of the V-shape by folding the outer part down and marking the fold with a clip or pin. Repeat on the other side.
Now add the ears. Place each ear at the middle mark, wrong side to right side (the front side of the ear should face you), and sew it in place within the seam allowance – less than 1 cm from the edge.
Next, fold the V-shaped openings right sides together and sew the area with a 1 cm seam allowance, securing the ears in place.
Sewing the Wool Kids’ Hat – Appliqué
To appliqué the face, use fusible webbing to keep it in place.
Trace each face element by color onto fusible webbing with a pencil. For example, draw the large and small dino eyes separately.
Cut out each traced piece roughly without following the line; we’ll cut more accurately after attaching the fusible webbing to the fabric.
Now place the fusible webbing on the wrong side of the appliqué fabric and press it following the manufacturer’s instructions.
Next, cut out each piece precisely along the lines.
To embroider the unicorn’s eyes (or the dino’s mouth), trace the shape onto embroidery film with a pen.
After arranging the appliqué pieces, peel off the backing of the fusible webbing and carefully iron the cheeks in place.
Adding the Unicorn Mane and Horn
Now your unicorn needs its mane and horn. Take the outer hat, the jersey strips, and the prepared horn.
For the forelock and mane, place the strips in front of and behind the ears, leaving about 1 cm at the top. This makes the mane durable enough for tugging.
Position the horn at the top seam, so its seam lines up with the hat’s seam.
Fix the mane and horn within the seam allowance to keep them in place.
Fold the remaining side of the outer hat over to meet the side with the mane, pin it, and sew with a 1 cm seam.
Give the Unicorn a Trim
Now your unicorn might need a trim! Cut the jersey strips to your preferred length, leaving the forelock shorter and the mane longer.
Finishing the Kids’ Hat
Optional: Adding Cords
If desired, add cords to the ear flaps. For the ideal length, hold the cords against your child’s head and adjust.
Complete the Inner Hat
Like the outer hat, fold the inner hat top together, leaving an 8-10 cm opening at the back for turning later. Use an elastic stitch for jersey.
Joining the Outer and Inner Hats
Almost done!
Turn the outer hat inside out, so the wrong side is facing out, and place the inner hat inside, with right sides together.
Pin the lower edge, ensuring the seams and all pieces of the outer hat (cords, mane, etc.) are inside.
Sew the edge with a 1 cm seam allowance. Then, turn the hat right side out through the opening.
Close the turning hole neatly, then topstitch around the lower edge of the hat to keep the lining in place. Slightly roll the edge inward for a clean finish.
And you’re done! Your cozy, colorful unicorn hat is ready to keep little ears warm.
Be sure to check out the dino hat version – Part 2 is coming tomorrow!
Kids’ Hat Sewing – Free Pattern Download
Here’s the free pattern download for the unicorn hat. The pattern is in German, but I’m sure you will be able to manage. Please note that the main part needs to be cut on the fold (in German: “im Bruch”). Happy sewing!
Download Unicorn Pattern (PDF, A4 format)
beautiful and sweet