Learn How to Make a Scrub Cap! Free PDF Pattern, Sewing Tutorial, and Step-By-Step Video! Scroll down for all the info! 

We have all heard the news. Our healthcare workers are in desperate need of Personal Protective Equipment (PPE). They are struggling to find scrubs and masks that they need to perform their duties. And now with states are trying to determine how to open back up, even more people are looking for masks (I have a few patterns for masks that I will link below). If you are looking for more ways to help the medical community right now, surgical scrub caps are another thing healthcare workers are asking for! This post has a FREE printable surgical cap sewing pattern that you can download and sew! Make a few matching masks and give them to a hospital in need! I heard that shipping dates for medical PPE can be anywhere from 6-12 weeks! Let’s support our healthcare workers and our community. We need to act, and act fast.

Our local hospital put a request out for scrub caps a couple of weeks ago, and I needed to mix it up a little. I have made over 800 masks , so making scrub caps was a nice change. I know that we have lots of talented crafters that are ready and willing to help. If you own a sewing machine, it is time to take it out and use it.

A Good Charity Project

I want to challenge everyone from beginners to experienced sewers to help our healthcare workers and our communities. This scrub cap pattern is meant for everyone! Thank you for giving back; however you can!

Scrub Cap Supplies

• FREE Scrub Cap Pattern
• Pre-Washed Cotton Fabric 16” X40”
• 4” of 1/4 Wide Elastic
• Sewing Machine or Serger
• Thread
• Scissors
• Pins
• Iron
• Safety Pin

Before you start cutting and sewing, find some fun fabric and make sure that it is pre-washed. This will pre-shrink the material and will remove any changes in sizing. Remember, it is a good idea not to use fragrant detergents, fabric softeners, or dryers sheets as these can cause allergic reactions in some.

Step 1.

Let’s Make a Scrub Cap – Print off & Tape Together the FREE PDF Pattern

Download the Free PDF pattern to your computer. Open it up, print at 100% with no scaling. There will be three pages to print out.

Tape the pattern together by matching 1A with 1B and 2A with 2B then, align the triangles and black lines on the DIY Scrub Cap Pattern. Before you cut out the pattern shapes from the printed sheets, trim the left side of the pattern piece 1B and tape this dot and dashed line to the dot and dashed line on the right side of the pattern piece. Matching top and bottom edges as well as the triangle markings. Repeat with pieces 2A and 2B.

Once both sets of pattern pieces (1A:1B and 2A:2B) are tapped together, cut out the pattern pieces along the outer solid bold lines.

Step 2.

Let’s Make a Scrub Cap – Layout Pattern & Fabric for your Scrub Cap

Laying out the Pattern:

Have your fabric folded in half so that you have selvages lined up and your fabric is about 20”x16”. 

Place pattern piece #1 on the prepared fabric so that the left and bottom edges of the paper pattern are aligned with the left and bottom folds of the fabric.

Pin in place and cut out using scissors and a rotary cutter.

With the remaining fabric or a contrasting fabric (if you choose), make sure that it is twice the width of the pattern piece #2.

Fold the fabric in half, longways, and press. Place the pattern piece onto the fabric aligning the long straight edge of the fabric, then pin and cut out. Once it is cut, you will have one single layer of fabric that has a somewhat oval shape; this is the top of the cap.

Tips for Seam Finishes:

In addition to stitching the fabric pieces together, it will be necessary for the seams to be finished with a zig zag stitch to control the fabric edges from fraying when worn and washed. This project is a perfect opportunity to use your serger too!

Sewing Machine Edges Finished

• Stitch a 1/4” seam, if you have a 1/4” foot even better!
• Re-stitch along the seams using a zig zag stitch
• Zig zag on the fabric edge 

Serger Edges Finished

• Use a 4 thread style, as the guide for your serger suggests
• If you are more comfortable, stitch the seam with your sewing machine and then serge the edges

Step 3.

Let’s Make a Scrub Cap – Assembling the Cap

Inserting Elastic

Place the cap top piece (#2) right side down on your work surface. Fold up the straight edge 1/4” and press, then fold up this edge again 3/4’ – 1/2” and press

Top stitch this folded edge very close to the edge to secure.

Using a safety pin, thread the elastic piece through the casing that you created on the cap top. Make sure you do not pull the elastic all the way through. I like to pin one edge of the elastic so this doesn’t happen. Once you have pulled it through and secured it with a pin, zig zag each side of the elastic to secure it to the cap top. 

Set aside for later.

Hem and Ties

Turn the long edge of the main cap side piece (#1) 1/4′ how you see in this photo.

Fold the long edge back on itself with right sides together along the hem fold.

Stitch starting at the end of the tie and along the edge just until you get to the curve. Secure the stitching at the beginning and the end. Repeat on the other end.

Once both ends have been stitched, clip the corners. Then turn right side out while making sure you get all of your corners completely out. There are tools you can use for this step, or simply using a pen would work. This makes sure the corners are nice and crisp. Now press!

Topstitch the hem in place

We are using a wide hem to keep any stitching or seams near the bottom edge of the cap. Any stitching or seam in this area can be uncomfortable on the skin for the person. 

Cap Construction

Pin the cap top (#2) and cap ties (#1) together along the raw edges, right sides together, and matching centers. Working out from the center, pin the edges together and 3/4” apart as you work your way to the end of the cap top.

It may be easier to stitch one side at a time, starting at the center and working out. Use as many or as few pins/clips as you feel comfortable, you may only need one center pin.

Stitch as slow or as fast as you are comfortable stitching. Stop with the needle down, as required, to adjust for sewing of the curve. Once both sides are stitched, go back and finish the raw edges with a zig zag stitch. Now it is the perfect time to use your serger.

Finishing 

Turn the right side out. As an optional step you can top stitch the seam down to give it a finished look.

CONGRATULATIONS YOU HAVE JUST FINISHED SEWING A SCRUB CAP!

Checkout this second version REVERSIBLE Scrub Cap tutorial!

Now that you’ve finished your scrub cap,  sew a matching face mask here! See the Tutorial Video below!

Don’t forget to join OUR Facebook group where you can show us what you’re made!  CLICK HERE if you would like to join the Facebook Group, Crafts and Inspiration hosted by Fun Stuff Crafts! In the group, I share and encourage members to share tips and projects.