I made Super Mario hats for my nephews a little while back.
I couldn’t find a pattern anywhere so, after much trial and error, this is what I came up with.
You can download the pattern here.
This pattern works for 4/5 year olds but can be adapted for older children/adults.


Cut 2 of each hat and visor piece (I used red fleece fabric – it was sturdy and soft at the same time and worked well to give the bulky, cartoony look of Mario’s hat)




Sew with right sides together


Cut the “M” out of white felt and stitch to front piece of hat


Sew visor pieces together (right sides together)


Turn right side out and insert piece of plastic or interfacing to add rigidity to the visor (on the pattern the dotted line marks the size of the piece of plastic or interfacing to be used – slightly smaller than the fabric pieces)


Pin visor to the hat


Sew visor to the hat


With right sides together sew hat pieces together all the way around the hat


Turn right side out and Insert polyfill to the front of the hat, on the inside (secure using hot glue)


Close the hat




Little J was not impressed – “This is for boys!”



  1. Krystal
    October 24, 2014

    How would you adapt this to fit an adult?

    • laura
      October 26, 2014

      I haven’t made an adult one, so I’m not sure. I would increase the size of the child-size pattern and measure your adult head size. All the straight edges of the pattern pieces added together need to be equal to the circumference of your head. Hope that makes sense! :) A friend of mine just dressed up as Mario last week and used a red baseball hat..that works too :)

    • Isaac James Powers
      August 31, 2015

      what i did and might be your anser is zooming in to the patten on a ew page and put paper on my computer monitur then drew it in 400 % it keeps the same shape exept larger sorry for my spelling but i hope this helped you

  2. mom2lo
    October 26, 2014

    Just to be clear… these hats are NOT designed nor intended to STAY on a child’s head, correct? I’ve made half an dozen from fleece as you suggested (rather than felt as several other tutorials have used), and not only are they HUGE for my 5 and 7 year olds, they do not in any way stay put on a child’s head as they walk slowly and steadily, much less as they run around a Mario-themed birthday party on a sugar high.

    So very disappointed. :(

    • laura
      October 26, 2014

      I made these hats for my twin nephews and they had a lot of fun with them. My child was a (somewhat reluctant:)) model for these and they also stayed on her head just fine. I’m not sure what went wrong with yours. Sorry it didn’t work out for you! You could maybe add some elastic in the back or a snapback (with velcro)..?
      I used fleece because I had some lying around. It was quite sturdy and thick fabric though, so maybe that helped.
      I also thought that the children might not like the felt. Felt does tend to be a bit itchy.

  3. KV
    October 28, 2014

    Thank you for posting this super cute hat pattern and instructions! I’m going to try to adapt it for my adult-sized head :)

  4. Isaac James Powers
    August 31, 2015

    thank you for posting this. this hat met all my expectations and more good job

  5. Abi
    September 13, 2015

    Thank you x I had to add a stretched piece of elastic at the back (thank you, Laura), and because I used fleece, I’ve only made it single layer; otherwise it gets too hot to wear x

    My kids love them – one red and one green x shame I can’t show you x

    Also, thank you to

  6. Kim
    September 24, 2015

    Is the downloadable pattern the correct size or does it need to be enlarged to fit a small six year old?

    • laura
      September 30, 2015

      Sizes vary but this should work for a 6 yr old

  7. Angela
    October 12, 2015

    Thank you for sharing…I made one for my son for Halloween, I thought it was going to be harder then it was super easy to follow and sew. It fits my 5 year old perfect. I am going to attempt to make an adult size next.


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