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Skull Cap Sewing Pattern Freeleadingdwnload

Hat Patterns to Sew. Here are sewing patterns for hats that keep us warm, are simply stylish and hats that keep the sun out of our face. The right hat can complete an outfit and also attratively frame a face. You can sew a hat for you or someone else by choosing one of the hat patterns listed 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!

This diy scrub hat pattern includes two variations with adjustable backs to fit both men and women. Scrub caps can be made with basic cotton, which is best for the hospital washing process. These can be reused and even made to match a surgical mask! An easy diy scrub cap and mask set would make a really fun gift for a nurse, doctor, vet, dentist or other healthcare worker!

There are two variations included, an all-in-one tie back and one with a binding across the bottom. Instructions are also given to add elastic to the back of the cap, which will give you a snugger fit around the brim of the hat.

  1. SKULL CAP, No Elastic Tie Back Pixie Skull Hat Sewing Pattern© sister8shop. From shop sister8shop. 5 out of 5 stars (1,592) 1,592 reviews $ 6.95. Favorite Add to Simple Skull Cap for Adults (Crochet Pattern) Banevale. From shop Banevale. 5 out of 5 stars (1) 1 reviews $ 2.00. Favorite Add to.
  2. Skull Cap Patterns I've read that you can measure the size on a wool sweater, using the bottom, waist area as the 'band' of the cap. Cut both sides of the sweater in an upside-down 'U' shape, turn the pieces inside out and stitch them together, then turn them right side out again.

Free Sewing Patterns To Download

Also see:
-3 Ways to Make a Face Mask
-Hospital Face Mask with Filter Pocket
-Kids Face Mask Pattern

Materials for Surgical Cap

  • 1/2 yard 100% cotton fabric such as quilting cotton
  • 1/2″ elastic (optional)
  • 1/2″ binding or bias tape (optional) or create your own with pattern
  • Pattern Pieces, download below

Free Scrub Cap Sewing Pattern

Scrub Hat Sewing Instructions

Use a 3/8″ seam allowance.

For the bow back variation, cut two top pieces and two side pieces from cotton.

Sew a baste stitch along the top of each scrub hat side piece. 3/8″ from the raw edge. I like to use about a 3-3.5mm stitch length so it doesn’t gather too much.

Match the cap top middle to the middle of the side piece and pin.

Pin the side piece all the way around the top, pulling the baste stitching as needed to fit. The tie part will not be pinned. Sew pieces together.

Clip seam allowance along the top of the hat and trim to 1/8″.

Repeat with lining pieces. Turn main inside out and lining right side out. Stack together matching all raw edges. Sew around the bottom edges of the scrub cap with a 1/4″ seam allowance. Pivot and turn around the ties and back of hat. Leave a small 2″ opening at the bottom of the hat.

Clip points and curves. Turn right side out and press well.

Topstitch along the bottom edges, closing the opening that you left. Tie the back pieces together and you’re done!

Surgical Cap with Binding Variation Instructions

For binding variation, cut out the side pieces using the dotted line indicated. Also cut 1 piece of binding 2″ by 44″.

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Assemble hat main and lining pieces the same way as stated above for tie back variation. Turn one right side out and the other inside out.

Skull Cap Sewing Pattern Freeleadingdwnload

Skull Cap Patterns Free Printable

Stack hat pieces together and match up at the back. Stitch together using a 1/4″ seam allowance. Clip corners and turn right side out. Press well and topstitch.

(Optional) To insert elastic for a snugger fit, cut a 2″ piece of 1/2″ elastic. Sew to the inside of hat where indicated on pattern piece. Sew between both layers of surgical cap.

Stretch the elastic to the other marking on pattern piece and sew again. Pull elastic and sew along the top so elastic won’t move. Let go and hat with gather at the back. Repeat on other side.


To create binding, fold long edges of strip in so they almost meet in the middle and press. Fold in half again and press.

Pin binding over raw edge at the bottom of the surgical cap and topstitch. Fold the ends of the binding under and sew.

Create a 1/2″ pleat on each of the side backs. Stitch down.

Free Pattern For Skull Cap

Done! Make a matching mask from one of these posts:

-3 Ways to Make a Face Mask
-Hospital Face Mask with Filter Pocket
-Kids Face Mask Pattern