Fleece hats are very simple, and can be easily made from fleece remnants at your local fabric store.

Materials:

Fleece (one or two colors works well)
Matching thread
Optional - A bit of muslin for a nametag
Optional - Some buttons or other decorations

Tools:

Sewing machine
Cutting implements

Step 1: Cutting

I used two colors for this hat. Measure your target head. For reference, my target head was 21 1/2" around.

For the top part, measure a rectangle that is a bit longer than your measurement, and about a third of that on the other end. In the example, I went with 23" by 7 1/2" for the white piece.

For the bottom part (the ear covering), measure the same length (23" in this case), but only 4" tall.

To cut the top part, fold it in half twice as shown in the pictures so you can easily cut four equal pieces. I just freehanded this shape. The longer you leave the straight edges, the blockier the hat will be at the end.

You now have a piece with four lumps.

Step 2: Sewing the Top

Keeping the "good" side in the middle, fold the 4-lump piece in half to make a 2-lump piece.

Sew the long open curve first, up to the tip of the hat. Then, sew the opposite side.

Step 3: Sewing the Top (continued)

Pull the remaining two sides apart so the un-sewn curved edges are lined up, as in the pictures. This time, sew all the way across the top, crossing right over the sewn tips from the last step.

I like to feed that very tip part through like an "S" shape, so on top, the excess is folded toward the machine, and on bottom, the excess is folded toward me. This makes it so I'm not sewing through 6 layers of fleece right there.