They do have some baby mickey ears available. They come with an elastic strap that goes under the chin so the ears will stay on easily. We bought our daughter a pink set last year (she was around 1). Honestly, though they still were just alittle big, but we managed.
They also have some that fit my BIG head, and if they fit me they should fit anyone.
The only place I've seen put the names on the hats is at Le Chapeau at MK. It's two dollars extra for the names... I had no problem getting them on baby hats.