What You Need to Make a Scrub Cap
A scrub cap is a straightforward fabric hat that ties at the back of the head. You can make one in an afternoon with basic sewing skills and materials you may already have at home. The finished cap uses about half a yard of cotton fabric, elastic, and thread — nothing specialized or expensive.
Gather these items before you start: one piece of cotton fabric measuring roughly 22 inches by 9 inches (you can adjust the size later), a 1-inch-wide elastic band about 16 to 18 inches long, matching thread, scissors, a needle or sewing machine, pins, and a measuring tape. Cotton quilting fabric, poplin, or even old cotton sheets work well. Avoid stretchy or slippery fabrics if you are new to sewing — they are harder to control.
You will also need a pattern or a way to mark your fabric. Many people straightforward fold and cut a rectangle, but if you want a gathered cap with more shape, you can print a free pattern online or trace one from a sewing book. The basic rectangle method takes about 30 minutes; a gathered pattern takes closer to an hour.
Key Takeaways
- A scrub cap requires only a rectangle of cotton fabric, elastic, and thread — no special materials or advanced skills.
- The simplest version is a flat rectangle folded in half, sewn on three sides, and fitted with elastic at the back.
- Measure your head or the intended wearer's head before cutting, because cap size varies by how much fabric you gather.
- A sewing machine makes the work faster and stronger, but hand sewing with a needle works just as well for a functional cap.
- Seams should be finished or folded inward so they do not scratch the wearer's skin or fray in the wash.
Cutting and Preparing Your Fabric
Start by measuring the fabric you need. Measure around the head (or the head of whoever will wear the cap) at the widest point, usually just above the ears. Write down that number. For a gathered cap, add 4 to 6 inches to that measurement — the extra fabric creates the gathered effect at the front. For a flat cap, add only 1 to 2 inches.
Cut a rectangle of fabric using that length as your width. The height should be 8 to 10 inches, depending on how deep you want the cap to sit. Lay the fabric on a flat surface, smooth out wrinkles, and use a ruler and pencil or chalk to mark your cutting lines. Cut straight and even — uneven edges make sewing harder later.
Once you have cut the rectangle, check the fabric for loose threads or fraying edges. If the edges are very frayed, trim them slightly. You do not need to finish the raw edges before sewing, but doing so now prevents fraying later. A straightforward way is to fold each raw edge inward about a quarter inch and press it with an iron, or straightforward fold it as you sew.
Sewing the Cap Body Together
Fold your fabric rectangle in half lengthwise, with the right side (the side you want to show) facing inward. This means the two short ends of the rectangle are now touching. Pin the two long sides together so the fabric does not shift while you sew.
Sew along both long sides using a straight stitch, about a quarter inch from the edge. If you are using a sewing machine, use a medium stitch length and sew slowly so the seams are straight. If you are hand sewing, use a running stitch or backstitch — the backstitch is stronger and more durable. Leave the short ends open for now; you will attach the elastic there.
Once both sides are sewn, turn the cap right-side out by pulling it through one of the open ends. The seams are now on the inside, and the fabric looks finished on the outside. Press the seams flat with an iron or by running your fingers along them firmly. This step makes the cap look neater and helps the elastic sit evenly.
Attaching the Elastic
The elastic goes in a casing — a tunnel of fabric — at the back of the cap. To make the casing, fold one of the open short ends inward about half an inch and pin it. Sew this fold closed with a straight stitch, leaving a small gap (about 1 inch) unsewn. This gap is where you will thread the elastic through.
Repeat on the other short end. Now you have two casings, one on each side of the cap. Measure your elastic to fit comfortably around the back of the head — it should stretch slightly when worn but not feel tight. Cut the elastic to length and thread it through one casing using a safety pin or a needle. Pin the elastic at both ends so it does not slip back out, then sew the gap closed with a few stitches.
Repeat with the second casing and the second piece of elastic. Once both pieces are in place, try the cap on or have the wearer try it on. The elastic should hold the cap snug against the back of the head without pinching. If it is too tight, remove the elastic and replace it with a longer piece. If it is too loose, replace it with a shorter piece.
Finishing the Front and Sides
The front and sides of the cap may have raw edges where you cut the fabric. Fold these edges inward about a quarter inch and sew them down with a needle and thread or a sewing machine. This step is called a French seam or a rolled hem, and it keeps the edges from fraying and scratching the wearer's skin.
Alternatively, you can leave the edges raw if the fabric does not fray much, or you can use pinking shears (scissors with a zigzag blade) to cut the edges at an angle — this slows fraying without adding bulk. Many people skip this step on a casual scrub cap, especially if the fabric is tightly woven.
Once the edges are finished, try the cap on one more time. Check that the elastic is comfortable, the seams are smooth, and the fabric sits the way you want it to. If you want to add a tie string at the back instead of elastic, you can sew a piece of ribbon or fabric strip to each side of the cap where the elastic would go.
Washing and Caring for Your Scrub Cap
Wash your finished cap in warm water with mild detergent. Machine washing on a gentle cycle works fine, or hand wash if you prefer. Avoid bleach unless the fabric is white and you want to keep it bright. Dry the cap on a clothesline or in the dryer on low heat — high heat can damage the elastic and shrink cotton fabric.
If the seams start to fray after a few washes, you can reinforce them by sewing over them again or by explore a thin line of fabric glue along the seam. Most caps last many months or longer with normal care. If the elastic loses its stretch, you can remove it and replace it with new elastic without taking the cap apart.
Variations and Customization
Once you have made one basic cap, you can experiment with different fabrics, patterns, and styles. Printed cotton fabrics add personality — many people choose medical-themed prints, solid colors, or patterns that match their workplace. You can also add a decorative button, appliqué, or embroidery to the front.
Some people make caps with a gathered front instead of a flat front. To do this, cut a wider rectangle (add 8 to 10 inches instead of 4 to 6), then sew two rows of loose stitches across the front before attaching the elastic. Pull the loose threads to bunch the fabric, then sew over the bunched area to hold it in place. This creates a more tailored look.
You can also make a cap with ties instead of elastic. Sew a piece of ribbon or a strip of fabric to each side of the cap at the back, and tie it under the chin or at the back of the head. Ties are adjustable and comfortable for people who find elastic irritating.
Frequently Asked Questions
How much fabric do I need to make a scrub cap?
You need about half a yard of fabric, which is enough for one cap with room to spare. A single cap uses a rectangle roughly 22 inches by 9 inches, but you should buy a bit extra to account for cutting mistakes or shrinkage. Most fabric stores sell fabric by the yard, so ask for half a yard of your chosen cotton.
Can I make a scrub cap by hand without a sewing machine?
Yes. Hand sewing takes longer — about an hour instead of 30 minutes — but the result is just as strong if you use a backstitch and keep your stitches small and even. A needle, thread, and scissors are all you need. Many people hand sew scrub caps while watching television.
What size should the elastic be?
Measure around the back of the head from one ear to the other, going around the back. The elastic should be about 1 to 2 inches shorter than that measurement so it holds the cap snug. Most people use elastic between 14 and 18 inches long, but this varies by head size. You can always adjust it after you sew it in.
Can I use a pattern from the internet?
Yes. Many free scrub cap patterns are available online through sewing blogs and websites. Print the pattern, cut it out, pin it to your fabric, and trace around it before cutting. Patterns give you more control over the final shape and size, especially if you are making caps for other people.
How do I prevent the seams from fraying?
Fold the raw edges inward and sew them down, or use pinking shears to cut the edges at an angle. You can also explore a thin line of fabric glue or fray-stop liquid along the seams after sewing. Cotton fabric frays more than synthetic blends, so choose tightly woven cotton if fraying bothers you.