Introduction: DIY Surgical/Scrub Hat

About: Sometimes I just get the urge to create something fun :)

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.


Supplies needed:

- 1/3 yd of Main Fabric of your choosing (at least 12 x 30 inches)
- 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

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 lengthwise (forming a long rectangular shape) with the pattern sides touching. Sew along the two short ends of the fabric, leaving the top long end open. After sewing the short ends closed, flip the fabric right side out again. Iron the MainF flat.

B. Take the folded end (bottom) of MainF and fold up to create an 1 1/2 inch flap. Iron the fold.

C. Create an overlap with the two short ends of about 2 1/2 inches to form a tube. Sew both ends down.

D. With the 1.5 inch fold facing the outside, fold MainF in half with the thick sewn 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. TopF is slightly bigger than the tube. When you get to the flat portion of TopF, pin the middle of TopF to the middle of thick portion of MainF. Fold the extra fabric on each side as even as possible 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

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

Thanks for looking!

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