How to Make an Octonauts Hat

📝 This post,  How to Make an Octonauts Hat, was originally published in 2013 and has been updated with new information and resources.

Looking for an easy DIY Octonauts hat for a birthday party or pretend play? These homemade Octonauts hats were a HUGE hit at my son’s Octonauts birthday party and were surprisingly simple to make!

It’s been years since my boys watched the Octonauts, and honestly, I still miss it. The show had the perfect balance of learning, humor, adventure, and adorable characters. Kwazii was always my boys’ favorite, but I was partial to Peso.

So when my son requested an Octonauts theme for his 4th birthday party, I was quick to agree! Along with Spiderman and Paw Patrol, it became one of our favorite birthday themes.

The first item on my party planning list? Homemade Octonauts hats for all the party guests!

📝 While updating this post, I discovered that there are now many places online where you can simply purchase Octonauts hats. However, I’m still a little old-fashioned and enjoy making my own party decorations. Making the hats also gave my boys a chance to help with the party preparations, which made it even more special.

Materials Needed

✔️Octonauts blue (turquoise) craft paper
✔️white craft paper
✔️glue
✔️scissors
✔️computer/printer
✔️empty cereal box or other cardboard
✔️navy blue cording (available at craft stores by the yard)
✔️elastic or ribbon

How to Make the Octonauts Hat

Here’s how we made our homemade Octonauts hats!

✔️I began by finding an image of an Octonauts hat online and used it to make a stencil. I opened the image in a blank document on my computer, enlarged it, and printed two copies.  

✔️ I glued both copies to a cereal box, but any cardboard will do. I then cut out the two parts of the hat as shown in the photo below.

✔️ I traced the stencils onto the blue paper and cut out enough for all our guests.

✔️ Using an X-Acto knife, I carefully cut a slit in the bottom portion of the hat. See the image below for reference.

✔️ I added the blue cord around the outer edge of the bottom of the hat.

 ✔️I then slid the top of the hat into the bottom.

Making the Octonauts Logo:

I used the same process as above to create the logo. See the images for more details.

✔️ I searched for an image I liked, put it in a blank document, enlarged it to the size I wanted, and printed two copies.

 ✔️ I glued the two logos to cardboard and cut out each part: the squid and the circle. This was now my stencil for the logo

✔️I traced the two parts of the logo onto white cardstock.

 ✔️ I used a hole punch and blue paper to make the eyes and mouth. 

✔️ When everything was dry, I attached an elastic to the back so the children could wear their hats during the party.

Finished Octonauts Hats

And that, me hearties, is how we made our very own Octonauts hats. These homemade Octonauts party hats also make a fun craft activity for an Octonauts birthday party.

If your little one loves the Octonauts as much as mine did, these DIY Octonauts hats are such a fun addition to an Octonauts birthday party or pretend play day. They were easy to make, inexpensive, and the kids absolutely loved wearing them throughout the party.

Have an Octonauts fan at your house? Let me know who their favorite character is in the comments!

More Octonauts Party Ideas:

Kwazii Kitten Pirate Flag Shirt

Well, Shiver me Timbers– It’s the Octonauts!

Make Your Own Treasure Chest- Octonauts Style!

Octonaut Birthday Magnets