My most recent project was to design and sew 26 superhero capes for a 6th birthday party my son attended. While it sounds like an impossibly huge undertaking, I had help and it was just too much fun to feel like work.
1. Start with a 30″ x 30″ square of fabric. We used a fairly heavy but inexpensive ($7.99/yd) satin/polyester blend and were able to get 4 capes per yard of fabric. You’ll also need a contrasting fabric if you want to put a design on the back.
2. Using a plate or other round object and a piece of chalk, draw and cut a half-circle for the neck.
3. Finish the neck edge using either a rolled hem, or a serger.
4. Pleat the edges on either side of the neck edge and stitch in place.
5. Finish the remaining side and bottom edges with a narrow hem.
6. Fold the pleated edges an inch towards the inside and stitch in place.
7. Sew or hot glue squares of velcro to the corners of the pleated edges. Make sure that one piece of velcro is on the right side of the fabric and the other is on the wrong side of the fabric.
8. Decide on what design you want on the back of the cape. We used a lightning bolt for most of the capes and the birthday girl’s initial to set her apart. Draw your lightning bolt onto heatbond (available in most sewing sections).
9. Iron the heatbond onto the wrong side of your contrasting fabric and cut it out. Peel off the paper backing, then iron the lightning bolt onto the back of the cape.
For a really professional-looking finish, you can then stitch around the outside of the lightning bolt with a tight zigzag in a matching thread. (We did not do this because we had 26 capes to complete in time for the party and we’re not masochists.)