Since you mentioned making square pillows, I wondered if you couldn't just make a square pillow the size you want (right sides together, sew around leaving a hole for turning which will be hand sewn closed after stuffing) except when stuffing it, first sew a small square shape in the middle before stuffing then stuff the rest of the pillow form. There would be no hole in the middle but since you sewed a square there with no stuffing, it would not press against the ear. That seems like it might be the easiest and fastest way to make one. Hope this makes some sense to you when you read it and hope it is doable. Sometimes what is in my head does not always work. Nice of you and your group to volunteer to do this.