Instructables
Picture of DIY Surgical/Scrub Hat
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Working in the OR, I always see doctors and nurses walking around wearing cute scrub hats. So not wanting to wear those stupid looking blue disposable ones, I looked into purchasing a few. After seeing the outrageous prices some companies were charging, I set out to make my own. Challenge accepted. I couldn't find a decent *free* pattern online so I ended up just creating my own.

Enjoy!

Supplies needed:

- 1/3 yd of Main Fabric of your choosing. (If 44 inches wide, should be enough for both pieces)
- Accent Fabric (or scrap fabric) that is at least 8 1/2 by 11 inches
- 1/2 inch wide Elastic Band
- Ruler and/or Measuring Tape
- Pins
- Scissors
- Sewing Machine and Thread (matching your fabric)
- Iron/Ironing Board
 
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Step 1: Step 1: Cutting the Fabric

You will need to cut out two pieces of fabric. One of for the main body of the hat and one for the top. (Use the iron to help flatten out the kinks and folds in the fabric before cutting.)

For the main body of the hat, cut a rectangular piece of fabric with the dimensions 12 x 30 inches. 

For the top of the hat, I created a pattern using one 8 1/2 x 11 sheet of paper. Just make sure that one end of the fabric is flat. A sample of what it should look like is included. 

Step 2: Step 2: Sewing

Main body fabric = MainF
Top fabric = TopF
**Sew all edges with 1/4 inch seam**

A. Take MainF and fold it hot dog style with the wrong sides touching. Using the iron, flatten the fold along the bottom. Flipping the fabric inside out, sew along the two ends of the fabric, leaving the top open. After sewing the ends closed, flip the fabric right side out again. Iron the ends flat.

B. Take the closed end of MainF and create an 1 1/2 inch flap. Iron the fold. 

C. Create an overlap with the two ends of about 2 1/2 inches. Sew both ends down. 

D. With the fold facing the outside, fold MainF in half with the thick end on the left. Fold TopF in half with the flat portion facing towards you. Line up the two fabrics right sides together. Pin together along the edge of the entire hat, leaving the flat portion of TopF unpinned.

E. This is the trickiest part. When you get to the flat portion of the fabric, pin the middle of TopF to the middle of thick portion of MainF. Flag the extra fabric and sew this extra portion down. If confused, please refer to the pictures. I tried to provide as much help as possible. 

F. Sew MainF and TopF together leaving an 1/4 seam along the edge. 

Step 3: Step 3: Adding the Elastic Band

After sewing the two portions together, flip the hat. The folded flap should be on the outside now. 

Cut about a 6 inch long piece of elastic band. Start with either the left or right side of the thick portion of the hat. About 4 inches from the edge, sew the elastic down on the inside of the flap. Sew down the flap to the fold and along the edge to the other side. Close up the gap by sewing down the other end of elastic 4 inches from the other side. After releasing the hat, it should scrunch together. 

Note: If you feel the hat is still too loose, you can either shorten the length of the elastic or sew further out from the middle of the hat.


Step 4: Step 4: Reaping the Compliments

Picture of Step 4: Reaping the Compliments
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Final outcome: One Awesome looking surgical/scrub cap modeled by my good friend Totoro! Great for work, halloween costumes, christmas gifts, cooking, shower cap, etc...

Good luck! I would love to know how your scrub hats turn out :D

I'm working on a men's version of the hat. Will post up if any interest. Thanks for looking!


its totoro!!

myrhino6 months ago

I am so excited I found your surgical scrub hat! And was
wanting to make one for my brother in law.. I saw at the end of the post
you said that you were working on a male size/version... was wondering
if you had ever finished it...or if you could guide me as to what I
would have to change to make this one work for a man

bhinchman8 months ago
Love your scrub. I was looking for a child's pattern for my Grandson who loves to play Dr. Do you have a small scale size. Thank you.
shannonj741 year ago
OK, so this is old news for everyone but me. Thank you for the fantastic pattern and my bestie (OR nurse in Portland, Orrygun) is completely PSYCHED. Now I'm the hero, thanks to you. Which makes you awesome-er.
hellopf1 year ago
Nice tutorial. Could you possibly post a pic of you (or another person) wearing the hat so I can get an idea of how it looks on a real person? Totoro is really cute but it is hard to tell about how it will fit on a human head. THANKS!
wildcat03 (author)  hellopf1 year ago
Sure! Does this help?
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Nice work. I'll have to pass this along to my wife. She is an L & D nurse and likes to wear fun hats in the OR.
wildcat03 (author)  Kurt E. Clothier1 year ago
thanks!
Awesome hat and great instructions! Also, I love that you showed off your hat by putting it on your Totoro! You should really put a picture of Totoro wearing it in the intro step - It's awesome!
wildcat03 (author)  Penolopy Bulnick1 year ago
thanks for the suggestion!