The Best DIY Ear Warmer Headband

Make the best ear warmer headband for your kid, one that actually stays in place, protects the child in wind, but does not make him too hot. A perfect fall kids accessory you can make in a really short time. Did I mention it's a beginner sewing project? Easy and fun!

And there is a PDF sewing  pattern available in 8 sizes - and email subscribers can download the smallest 3 sizes (baby to 1 year) - join for free here
ear warmer headband

This post includes affiliate links. Thanks for your support!

Would you like to add a pop of color to your kids' fall wardrobe and let them stay warm outdoors this fall?

Then let's not lose any time - in short, I'll tell you why I love these earwarmer headbands. And why you'll love them too:

  1. PERFECT FOR FALL: They're wide enough to actually protect the head from wind (but don't make the kid sweat like those winter fleece ones!)
  2. Ear flaps fully cover the ears (but don't obstruct the kid's eyes!)
  3. Stays in place (no slipping during the play!)
  4. Easy and inexpensive to make.
  5. A great scrap buster!
  6. Make a great and easy homemade gift!
  7. You can get a FREE PDF sewing pattern in 3 sizes (scroll down). Yey!

Now, are you in? Let's make an earwarmer headband together!

You'll Need:

ear warmer headband

You'll need:
  • a 10"by 18" piece of cotton blend jersey
  • sewing thread (here I used a thicker, contrasting thread to make it easier for you to follow the tutorial)
  • sewing machine
  • ballpoint needle (A must for sewing knits.)
  • iron
  • scissors
  • pins
  • pattern (make or get one - my newsletter subscribers can have mine!)

I used a 5.8 oz weight jersey for this tutorial, it's a 95% cotton + 5% spandex blend. It has a moderate stretch.

You can use your fabric scraps, this is a great scrap-buster project. But if you are looking for some adorable new jerseys, feel free to check out these cute fabrics by peek-a-boo.

Your PDF sewing  pattern

Join Free Newsletter to Get Your Free Pattern HERE:

First things first: you can get your free PDF headband pattern for the smallest three sizes (baby to 1 year) using this subscribe link. I've made it available to all subscribers of AppleGreen Cottage and it's one of the thank-you freebies for joining me on the creative journey.

ear warmer headband

Plus, you get access to the entire subscriber-exclusive FREEBIES library! Here:
join the newsletter and get access to free pattern library

(If you’re already a subscriber, you can access the pattern with the password in each newsletter, in the resource library HERE.)

access free resource library
ALREADY GOT YOUR PASSWORD? LOGIN RIGHT HERE, with the password from the newsletter.

Headband Sizing

The free pattern comes in 3 sizes (baby to one year):

ear warmer headband

You'll notice that the sizes are a bit larger than the regular headband sizes. This is due to a wider, ear-covering form that will stretch less than the thinner variations of headbands we usually see in the market.

Need A Larger Size?

No problem. If you need a different size, have a look at the Best Earwarmer Headband PDF Pattern with tutorial in my shop. It's not free, but with the additional sizes up to adult sizes (total 8 sizes), you should be covered for life :)

It comes in 6 kids + 2 adults sizes  (total 8 sizes), complete with instructions and sewing tips. You can check it out here if you like:

ear warmer headband
Check out the full pattern HERE.

DIY Earwarmer Headband TUTORIAL

To make it even easier for you, the how-to is split into three sections. Makes it even easier to follow!

A) The Perfect TEMPLATE

You can make your own template or choose one of my patterns to make your project really fast!

You can:
a) Download your free pattern in 3 smallest sizes (3 months - 1 yr) here:

ear warmer headband

b) OR, if you need a larger size, download the complete, 8-size pattern in the pattern shop. It's not free, but with the additional 5 sizes (baby+toddler+kid-teen+adult), you could use it for everybody in your family.

ear warmer headband

Yes, it includes two sizes for you and your spouse too! :)

c) OR, you can draw your own template: wrap a piece of your fabric around the kid's head and add the 0.5 cm for seam allowance. You'll also need to add ear flaps, which may be a bit tricky - you need to catch the right position (exactly covering the ear area, not too far back or close to the front.) You might need a bit of a try-and-test approach. I'd suggest this only if you've got enough time and fabrics for a second/third try.

TIP: No matter how you start, always measure your child’s head to be sure you are making the correct size

ear warmer headband

ear warmer headband

B) CUTTING the Fabric

1) Draw or download your earwarmer headband pattern.

2) Lay the piece of jersey on a flat surface, right side up (=facing you), with the stretch running side to side. Usually this means that you'll see the tiny ribs running vertically.

ear warmer headband tutorial

Stretch direction is VERY IMPORTANT here!

3) Fold your jersey twice:

ear warmer headband

  • First, grab the right edge and fold it in half. Now you've got the fold on the right side and the jersey right-sides-together.
  • Second, grab the folded upper edge of the fabric and fold it in half by placing it onto the bottom edge. Now you've got four layers of jersey nicely stacked.

4) Place the template over the four layers. Please make sure that one corner of the template (marked by a red dot!) is placed on the 4-fold corner of the jersey! Add a 1/4" seam allowance on two sides (as marked in the template.) Then cut. 
ear warmer headband for kids

TIP: Always measure your child’s head to be sure you are making the correct size.

5) Unfold the cut fabric once so you get this double-layered piece (i.e. folded only once):

how to make ear warmer


1) Now you've got the piece of jersey folded once, right-sides-together (face-to-face) along the long line. Start sewing approximately 2 inches (5 cm) from the edge and stop at least 2 inches before the end. Seam allowance: 1/4"

ear warmer headband pattern

(The seam in this photo is a bit wavy because I used my regular foot. If you've got a walking foot, use it, the seam will look nicer!)

2) Secure stitch, then trim any excess fabric on the curved part (this way you'll reduce bulk and the curved part will look nicer.). Then turn the sewn piece right side out. Press.

ear warmer headband pattern

3) Now pin the short ends of the headband, right-sides-together, like this:
ear warmer pattern

4) Sew them together using a 1/4" seam allowance, backstitch as needed to secure.

ear warmer pattern

5) Tuck the sewn part back to form a tube-like headband. Press. Now you'll be able to finish the missing part (2 inch + 2 inch) of the  horizontal seam: topstitch over these 4 inches (zigzagging, remember!) Or, even better, use a ladder stitch if you have time to stitch it by hand.
ear warmer pattern

6) Done! You've just made a perfect headband for a kid.

headband pattern

Now you've got a cute headband in the color of your choice...

And here's a video slide-show for those of you who prefer video how-tos. Check it out here:

headband pattern

And if you're not ready to start working with jersey yet, fear not. Just select the fabric and wait a bit. In one of my next posts, I'm throwing in several sewing tips for beginners, and above all: TWO basic things that REALLY matter when sewing with knits. Like, really important. They can save your project. And make you totaly confident with cutting up and sewing your jersey piece. Actually, you'll just want to sew more of these headbands. Get your fabrics ready, subscribe to get your free template and pin this tutorial for later ;)

ear warmer headband pattern

Pin For Later:

The best earwarmer headband tutorial and 8-size PDF sewing pattern. The smallest 3 sizes (baby to 1 year) are free to download for email subscribers. This perfect headband pdf pattern will add a pop of color to your kids' fall wardrobe AND let them stay WARM outdoors this fall.

Happy sewing!

Check out one of my most popular patterns:
sewing pattern applegreen cottage
Check out the Diaper Clutch pattern HERE.


  1. I need to make one of these for my daughter! Thank you for sharing at The Really Crafty Link Party this week. Pinned!

    1. Hi Teresa,
      thanks! If you send me a photo of the finished headband, I'll be happy to post it! Have a great day,

  2. I've signed up several times today to receive the earwarmer pattern and it does not show up in my email. You were recommended by another blogger, so I thought I'd let you know there may be issues. If you have information on how to get the free pattern so I can start working on it, it's appreciated.

    1. Dear (Follower), have you checked your spam folder, maybe it's there? (I've received tons of thanks messages from readers who subscribed, so I'm sure the file gets downloaded properly.) Or, I will gladly send it to you directly by email if you let me know your email (unfortunately, I can't see any of your contacts because your comment was posted anonymously) Have a great day,

  3. Perfect for your cool weather, Damjana, and a great way to use up scraps of fabric.

  4. Hi! Love these headbands....could I make it with fleece thick fabric....hope to hear from you....

    1. Hi,

      a good question! Yes, you can make them in fleece, but in this case, I'd advise you to add more seam allowance and you need to count with more bulk when sewing. Let me know how it goes!

  5. Thanks for the pattern. But did I miss something? How does it fasten together? Thanks!

    1. Hi, and thanks for reaching out. I believe you want to know how to make the headband out of the PDF pattern you've just received - just follow the sewing tutorial above, it's easy!

  6. So glad I found you early this morning. My adult son & I have become friends with his (pediatric) neurosurgeon because of repeat (100's) visits. I've been looking for something easy to make for his little patients. Being cared for by him guarantees at least one "bad hear day" and I've been looking for something to make that he can carry in pocket to give patients. Am so jazzed about your patterns! Imagine this ear warmer and a matching bandanna bib for the younger ones and just the ear warmer for the older patients . . . Just to disguise his "handiwork." Thank you, thank you, thank you! Inexpensive and functional. Hmm.

    1. Thank you, anonymous. Your message means a ton. All the best to you and your family,

  7. Thank you for the free pattern! I'm really excited about this pattern! Since I haven't worked much with jersey, I'm going to practice with some of my husband's old ripped up t-shirts. :D

  8. This is adorable and looks super snuggly! :) Lisa

  9. Oh these look so warm and cozy! Thanks for linking up at the Sew-spiration link party! all the best 😀

  10. Damjana, I get your e-mail and come to your site & can't get the patterns because it says sign-up again. what can
    I do to get the patterns to open for me?

    1. Hi,
      when you complete the sign-up, you'll get the confirmation email with your free pattern into your inbox.
      Is it possible that you have not yet completed the signup, or your email with the freebie landed in spam folder?

      HOW TO SIGN UP (and get the freebie):
      (1) you first enter your EMAIL to sign up, then
      (2) check your email inbox (and spam folder) to CONFIRM the signup, then
      (3) you automatically get your free PATTERN delivered into your INBOX

      Let me know how it goes. If you still need help, drop me an email and I'll be happy to do it for you.

  11. Last fall I purchased your baby to adult size ear warmer headband pattern. I made one for each of the 7 grandchildren (age 4 to 10) in a super soft minky, they absolutely them and wear them daily, also wear them under their winter hat which rarely covers the ears completely or rides up, exposing the bottom part of their ears when playing. This pattern suits our Canadian winter just perfectly and goes great into spring.
    I love mine too. Reason? I don't like hats because my hair is always either in a pony tail or bun, but need the ears and forehead covered during the winter.

    1. Yes!
      Thank you so much for your kind words, you've just made my day! The best possible way to utilize this tutorial - making tons of headbands, for all your loved ones. You must be doing a lot of sewing with that many grandchildren (a lucky bunch of kids, having a cool grandma like you, making new things, and that such soft ones!) Which reminds me of a lovely photo someone posted in my Craftsy store, with the adorable minky headbands in girly colours - is it possible it was you? I stil have no idea who did it, but love those too! If you ever decide to send me a photo or two, I'll be happy to add them to this post for others as an inspiration. Thank you again, wishing you an amazing spring with your grandchildren!

  12. Hi!

    I was wondering if you could help me figure out how to download the ear warmer pattern? My e-mail is already signed up for the newsletter...

    1. Hi

      thanks for reaching out - I'll be happy to send it over to you directly if you let me know your email address :)