Kids Hat with Appliqué

Posted by PFAFF®

Make these fun hats with your leftover jersey knit or fleece fabric. Simply download the pattern for the hat and the appliqué embroideries and you are good to go! No embroidery machine, no problem. Download the appliqué templates instead and sew them the traditional way.

You need:

  • PFAFF® sewing and embroidery machine
  • Decorative thread, 40wt rayon
  • Jersey knit or fleece 22”x 22" (56x56cm)
  • Cotton fabric for your appliqué
  • Sew-On Button Foot (item #820473096)
  • Button(s), 2 for car and 1 for bird
  • Stretch needle
  • INSPIRA® Stabilizer, tear-a-way or water soluble
  • Pattern for the hat
  • Embroidery designs or appliqué templates


Cut out the hat pattern in two copies and tape together.

Fold the fabric for the hat and arrange the patterns on top next to each other. The dotted line should be placed along the fold.

Cut out the hat. You will have a shape that looks like this:


Decide where you want to the embroidery to be, and hoop the fabric and stabilizer.

Insert a stretch needle.

Embroider the appliqué, adding the fabric when prompted.

Remove the fabric and stabilizer from the hoop.

Snap-on the Sew-On Button Foot to attach buttons (eye of the bird or wheels of the car). Place a button in the foot and attach the button using the button sewing stitch.

Sew the hat together
Start by sewing the curved seams together to form the top of the hat (marked with arrows in image below) using a seam and overcast stitch on the machine.

Place right sides together and make sure that the appliqué is on the inside of the hat.

Sew the long sides together, leaving an opening at one end. Turn the hat right side out and sew the opening closed.

Fold the lining to the inside. Done!

Download Template  Download Design


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Seems to be wrong download for the template/designs and where is the template for the hat?
11/29/2015 1:17:24 AM

Lois Daubney
Hi, I was attempting to download the templates for the hat and when I clicked on the button the designs are for the flower earrings instead.
Lois Daubney
11/29/2015 2:55:51 AM

Pat McCalla
where do I find the template for the hat?
the template on blog is the earring design when I download it.
11/29/2015 8:03:18 AM

the "download" buttons are backwards. Plus the "Template" is actually the design link but it has the earrings in it.
11/29/2015 9:08:45 AM

the download template is party earrings
11/29/2015 12:28:37 PM

This looks like it would be a great gift for any child or grandchild.

Sadly, the two downloads for this have the pdf file and the other download with what I assumed would be the applique stitches for those two appliques. However, the 2nd download is actually for the Party Earrings and not for the Kids Hat with Applique as it should be.

Can this be corrected please?
11/29/2015 12:47:37 PM

Linda Frick
The downloads are all messed up today. There are no embroidery designs and no template for the hat. The template download is the party earrings from a previous day.
11/29/2015 2:39:21 PM

Carina Thavelin
Thank you for letting us know about the errors. It has now been corrected!
// Pfaff team
11/30/2015 8:43:44 AM

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