Instructables

Step 2: Make a Pattern

Draw out a pattern using these dimensions as a guide.
Finished tuque sizes should be as follows:
X-Large: 24" circumference, 12" from top to bottom (unfolded, allows 2.75" for brim)
Large (Adult): 22" circumference, 11" from top to bottom (unfolded, allows 2.75" for brim)
Medium (Child or Youth): 20" circumference, 10" from top to bottom (unfolded, allows 2.75" for brim)
Small (Toddler): 18" circumference, 9" from top to bottom (unfolded, allows 2.5" for brim)
X-Small (Baby): 16" circumference, 8" from top to bottom (unfolded, allows 2.25" for brim)

Since the size of your embroidery pattern affects the width needed for your folded brim, choose embroidery designs that will fit well in the alloted brim size, or adjust your pattern accordingly. 

Add seam allowance as you see fit.  Since fleece doesn't fray, I added minimal seam allowance.
 
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