A scrub hat is a straightforward drawstring cap you can make in an afternoon with basic sewing skills

A scrub hat is a gathered fabric cap with a drawstring casing at the back — the kind worn in hospitals, clinics, and surgical settings. You can make one from two rectangles of fabric, a drawstring, and about an hour of sewing time. The construction is straightforward: you sew the two pieces together, fold and stitch a casing for the drawstring, and finish the edges. No pattern is required, and mistakes are forgiving because the gathered design hides uneven seams.

The finished hat should fit snugly around your head without gaps, with the drawstring pulled tight enough to stay in place during movement. Most scrub hats are made from 100% cotton quilting fabric or surgical cotton because these fabrics are washable, breathable, and hold their shape through repeated laundering.

Key Takeaways

  • A scrub hat requires two fabric rectangles (typically 21 inches by 9 inches), elastic or drawstring cord, and a sewing machine or needle and thread.
  • The basic construction involves sewing the two rectangles together, creating a casing at the back for the drawstring, and finishing the front edge with a fold or binding.
  • Gathering the fabric at the back with the drawstring creates the fit and allows the hat to adjust to different head sizes.
  • Most scrub hats are made from cotton fabric because it withstands frequent washing and maintains its shape in a healthcare setting.

Gather your fabric, thread, and notions

You will need two rectangles of fabric, each measuring approximately 21 inches wide by 9 inches tall. Cotton quilting fabric or surgical cotton works best because it is durable and straightforward to sew. You can find these fabrics at any fabric store or online retailer. Choose a print or solid color that suits your preference — scrub hats are often made in bright prints or solid colors that match scrubs.

You will also need drawstring cord or elastic for the back casing. Drawstring cord is typically 1/4 inch wide and comes in cotton or synthetic materials; elastic is usually 1/2 inch wide. A spool of thread that matches or blends with your fabric, a sewing machine (or needle if sewing by hand), scissors, pins, and a measuring tape round out your supplies. If you want a finished edge at the front of the hat, you can use bias tape, but this is optional.

Cut and prepare your fabric pieces

Cut two rectangles from your fabric, each 21 inches wide and 9 inches tall. Use a ruler and rotary cutter or scissors to make straight cuts. The 21-inch width will wrap around your head with a 1-inch overlap for seaming; the 9-inch height gives you enough fabric to gather at the back and fold for the casing.

If your fabric frays easily, you can trim the raw edges with pinking shears to reduce fraying during washing. This step is optional but extends the life of the hat. Lay both rectangles on a flat surface with the right sides (the printed or finished side) facing each other, and pin them together along three sides: the two short ends and one long side. Leave the remaining long side unpinned — this is where you will insert the drawstring casing.

Sew the main seams and turn the hat right-side out

Using a sewing machine set to a straight stitch, sew along the three pinned sides with a 1/2-inch seam allowance. Backstitch at the beginning and end of each seam to lock the thread. Remove the pins as you sew. Once the three sides are sewn, trim the corners diagonally (about 1/4 inch from the corner point) to reduce bulk when you turn the hat right-side out.

Reach into the opening and gently pull the fabric through until the hat is right-side out. Use a blunt object like a chopstick or the eraser end of a pencil to push the corners out fully so they are square and even. Press the hat flat with an iron on a low setting, paying special attention to the seams. The opening where you turned the hat should now be a clean edge ready for the casing.

Create the drawstring casing at the back opening

Fold the raw edges of the back opening inward by 1/2 inch on both sides and press with an iron to crease. Then fold the entire opening inward by another 1 inch to create a casing channel, and press again. This 1-inch fold will hold your drawstring or elastic. Pin the folded edge in place.

Sew along the inner fold line (the one closest to the inside of the hat) using a straight stitch, leaving a 2-inch opening on one side. This opening is where you will thread the drawstring through. Backstitch at the beginning and end. The casing is now complete and ready for the drawstring.

Insert the drawstring and test the fit

Cut a piece of drawstring cord or elastic approximately 12 to 14 inches long. Attach a safety pin to one end of the cord and thread it through the casing opening, working it all the way around the back of the hat until both ends emerge from the same opening. Remove the safety pin.

Try the hat on and pull the drawstring tight until it fits snugly around your head without slipping. Tie the two ends of the drawstring together in a knot, and trim any excess cord. If you prefer, you can sew the opening closed with a ladder stitch (an invisible stitch that closes the gap from the inside), or straightforward whip-stitch it closed with a needle and thread. Press the finished hat one more time to set all seams.

Finish the front edge if desired

The front edge of the hat can be left as a raw folded edge, or you can bind it with bias tape for a more polished look. To bind the edge, open the bias tape and pin it to the front edge of the hat with right sides together, then sew along the fold line of the bias tape. Fold the bias tape to the inside of the hat and sew it down by hand or machine for a clean finish.

This step is purely cosmetic and does not affect how the hat functions. Many scrub hats are worn with the front edge left as a straightforward fold, so binding is optional depending on your preference and skill level.

Care and storage of your finished scrub hat

Wash your scrub hat in warm water with mild detergent and dry it on low heat or air-dry it. Cotton fabric holds up well to frequent washing and maintains its shape. If the drawstring loosens over time, you can tighten it or replace it by opening the casing seam slightly, removing the old cord, and threading in a new one.

Store the hat in a clean, dry place. Many people make several scrub hats in different prints and rotate them throughout the week. Once you have made one, the second and third hats go faster because you understand the steps and can work more efficiently.

Frequently Asked Questions

What size fabric should I cut if I have a larger head?

Increase the width of each rectangle to 23 or 24 inches instead of 21 inches. The length can stay at 9 inches. Test the fit as you go by trying the hat on before you sew the casing closed. You can always adjust the drawstring tightness, but the overall width determines whether the hat will fit at all.

Can I sew a scrub hat by hand instead of using a machine?

Yes. Use a running stitch or backstitch to sew the seams, which will take longer but produces the same result. Hand-sewn seams are actually quite durable if you use a tight, even stitch. Make sure your thread is strong and knotted securely at both ends.

What if I do not have drawstring cord — can I use something else?

Elastic works well and is easier to thread because it is thicker. You can also use ribbon, cording from a craft store, or even a strip of fabric folded lengthwise. The drawstring just needs to be long enough to wrap around the back of the hat and tie securely.

How do I prevent the fabric from fraying in the wash?

Use pinking shears to trim the raw edges before sewing, or finish the seams with a zigzag stitch on your sewing machine. Washing in a mesh laundry bag also reduces fraying. Most cotton fabric frays minimally if the seams are sewn securely and the edges are trimmed cleanly.

Can I add elastic instead of a drawstring for a tighter fit?

Yes. Cut elastic to fit snugly around the back of your head (usually 8 to 10 inches), and sew both ends directly into the casing instead of threading it through. This creates a fixed fit rather than an adjustable one, so measure carefully before sewing the ends in place.