– 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
– Sewing Machine and Thread
– Iron/Ironing Board
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. Make sure that one end of the fabric is flat.
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 a 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.
F. Sew MainF and TopF together leaving a 1/4 seam along the edge.
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: Reaping the Compliments
Final outcome: One Awesome looking surgical/scrub cap.
Check out this video for more help – https://www.instructables.com/id/DIY-SurgicalScrub-Hat/