How to make a bunny ears headband

1. Materials & tools

Materials (For the adult size (26 cm ear height))

• Main fabric (white felt or boa) — about 40 × 60 cm (for 4 ear pieces)
• Contrast fabric (pink, for the inner) — about 20 × 40 cm
• Fusible interfacing or wire (to shape the ears) — a little
• A store-bought headband — 1
• Headband cover fabric (felt) — about 40 × 8 cm
• Sewing / hand-sewing thread

Tools

• Sewing machine (or needle and thread)
• Fabric marker or pencil
• Ruler and scissors
• Iron
• Pins or clips

2. Make the pattern (auto-generated in Katagami)

With the Katagami pattern tool, you just enter the finished size and it drafts a seam-allowance-included pattern, tiled to print at actual size on Letter or A4.

1. Open the tool
   Open the pattern tool and choose “Accessories” → “Bunny ears headband” from the tabs at the top.
2. Enter the size
   Enter the ear width, ear height and headband length. Presets for child, adult and long. Adjust the length to your store-bought headband.
3. Set the seam allowance
   Use the slider at the bottom (beginners: 1.0–1.5 cm / about 3/8–5/8 in).
4. Print
   Press “Print (actual size)”, then in the print dialog set Scale = 100% and turn “Fit to page” OFF. Check the 50 mm calibration box on the first guide sheet with a ruler.

3. Cutting the fabric

1. Prepare the headband
   Measure the length of your headband (end to end along the arc) and enter it; an ordinary one is about 30–40 cm.
2. Cut
   Cut 4 outer ears (2 layers per ear), 2 pink inner pieces and one headband cover. Felt can be left with raw edges.

4. Sewing

4-1. Add the pink inner

1. On the two ear pieces that will face front, sew a pink inner piece to the center, stitching all the way around like an applique.

4-2. Sew and turn the ears

1. Place two ear layers right sides together and sew all the way around, leaving the base open. Clip the curves so they turn cleanly.
2. Turn right side out through the base and insert interfacing or wire to hold the shape. Make the second ear the same way.

4-3. Attach to the headband

1. Fold the cover fabric, wrap it over the store-bought headband and sew along the edge.
2. Sew the two ears about 5 cm to each side of the center, tilting them slightly.

✏️ In felt the edges do not fray, so you can skip turning: stack two layers, sew around, and slip the interfacing between. Wire lets you fold one ear over for character.

5. Tips & variations

• Change the color: white and pink is classic; brown for a bear, gray for a mouse, black for a black rabbit.
• Pair with a tail: make the costume tail in white boa for a full bunny outfit.
• For Easter: pair with a tutu skirt for an Easter bunny costume.