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Cut four ovals from brown felt. Sew two ovals together to create an ear. Turn the ears inside out. Stuff the ears with polyester fiber. Pinch the ears in the middle to create their shape. Sew the ears to a headband.
Measure the ovals to be 6 inches tall by 4 inches wide. Depending on the age and size of the person wearing the costume, you may want to make the ears larger or smaller. Leave one of the short ends of the ovals unsewn. Use a sewing machine or hand stitch the fabric together around the edges. Push the fabric through the unsewn end to turn the stitching on the inside of the ear. Use pillow filling to fill the ears. Place enough filling to give the ears some volume. You do not need to stuff the ear completely full; a small wad in each ear is enough. Push the filling to the outside to create a full look around the exterior of the ear. Add more stuffing if you need to create a thicker ear. Place a few stitches in the center of the ear to keep the middle pinched together. Wrap the open ends of the ears around a plastic headband. Attach the ears to the headband by sewing the open ends together around the band.