DIY Surgical/Scrub Hat

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 (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!

Comments

[annemarieclermont]

beyond weird that I randomly clicked on this pattern while sitting next to the material I bought about 10 years ago!

[chicasiempre]

Can anyone please share the pattern with me. I only got the instructions but not the pattern. [e-mail], I would greatly appreciate it

[wildcat03]

Hi, the instructions does not include a pattern page. You will have to cut based on the measurements mentioned in the directions. One piece is 12 inches by 30 inches. For the other, grab a standard letter sized sheet of paper (8x11.5 in) to draw out the pattern. For sizing, please use the pictures in step 1 for reference.

[Xvazquez]

Hello, I am gettingvan error trying to download the pattern. If anyone could share it to me [e-mail] I would really appreciate it.

Take care, be safe, and stay healthy!

Thank you!

[wildcat03]

Hi, the instructions does not include a pattern page. You will have to cut based on the measurements mentioned in the directions. One piece is 12 inches by 30 inches. For the other, grab a standard letter sized sheet of paper (8x11.5 in) to draw out the pattern. For sizing, please use the pictures in step 1 for reference.

[AgnesCreates]

I really like your scrub cap sewing tutorial and the pattern! It is a smart idea to just put elastic on the back and not to worry about sewing on the ties. Since your cap has a wide band you can sew on buttons for the elastic loops of face mask. Look at my scrub hat to see what I am talking about https://thesewingpixies.com/surgical-cap-sewing-pattern/

[Llawson66]

Hello! I love the look and simplicity of your scrub cap and I’m sewing isolation gowns to donate as well. Can you tell me if you or anyone has a video showing and explaining the steps? Thanks so much!

[wildcat03]

There is not a video currently, but I did update some of the language within the instructions to clear some points up.

[justsnoopin]

This pattern looks great! Have you made a version for men?
Thanks

[wildcat03]

There is not a men's version at this time.

[PTjai]

Does anyone have a downloadable pattern they can share? I work in healthcare and hoping to make one ASAP

[Teeka58]

I have verified my info and it will not allow me to download it please email me a good download length

[Nicksgma1946]

need a version for men.......

[Shirleymariefergy]

I’m having trouble downloading the pattern. The site keeps asking me to verify my email, which I’ve done three times. Please send me the download so I can make these for my local hospital.

[L1nda50]

I've been trying to download the surgical/scrub cap info using the download button at the top, however it keeps asking to verify my e-mail, which I've done several times. I still can't get it to download. What might the problem be? Thanks.

[Sondracreason]

Is there a PDF version, how can I access it if so?
Thanks!

[wildcat03]

Once you login, there should be a download button at the top near the title

[LynKelley]

I do not understand the what you are doing to create the with the 1 1/2 inch flap. The fabric pattern makes it very hard to see what you have done. Is the flap the full length of MainF or is it the closed end of MainF. I can not tell what you have done here. Also I have the same question concerning the 2 1/2 inch end overlap.....

[wildcat03]

After folding the rectangle lengthwise, fold up the fabric to create a brim along the entire length that measures 1.5 inches. After folding this, create a tube by over lapping the short ends by 2.5 inches.

[austinangela]

I uploaded some photos under "I made it" to help clarify.