My 12 month old loves to throw her hats out of the pram while I'm not looking, so I decided I'd better start making them instead of having to buy them! This is what I came up with using polar fleece, and its very quick and easy to make on the overlocker (serger).
Cut out 2 of the top part of the hat (the top pieces). For my 12 month old the measurements are 8.5 inches across at the bottom and 6.5 inches from top to bottom, then draw in the curve in a nice round shape.
Also cut out a band that is 17 inches long and 9 inches wide.
You could adjust these measurements for an older child.
*IMPORTANT! Cut your pieces on the bias (diagnol) or your hat will have no stretch.
Lay your rounded hat pieces on top of one another with the right sides facing and overlock the round part, leaving the straight part open. Turn it the right way out when done.
Fold your band in half lengthways with right sides together and over lock the raw edges together (where the pins are in the picture) Then fold the band in half widthways so that the right side is facing out on both sides.
Now tuck the band inside the round hat piece so that all the raw edges are aligned together and pin to hold. Overlock right around the edge ensuring all layers are sewn together (the overlocker makes an easy job of this).
When you untuck the band, your hat should look like this.
Now simply fold the band up to cover the overlocked part and you have a lovely new hat. Easy peasy!