My husband came home this weekend and wanted some fabric surgical hats. He is tired of wearing the ill fitting disposable hats that are provided to him in the OR. So while he was home and I could measure his head, I got to work. You will need to fit off the following two sheets with no margins.
Cut out your pattern and tape the stars so that they match up when overlapped. I actually printed off two of the patterns and instead of having to place them on a fold, I could center them on my shirt perfectly. If you want to do it this way, just tape them together on the fold lines.
Place your patterns on your fabric, or in this case an old t-shirt. He wanted it comfortable, breathable, and with a cool pattern on it.
Pin the top of the hat to the top of the side piece, with right sides together. Then sew together with 1/2 inch seam allowance.
Take a ribbon and sew it around the bottom of the sides. Leave 6 inches hanging off both sides, which you will use to tie. Fold the ribbon up and sew along the edge giving it a finished look from the outside.
And there you have it. Easy as pie! A stylish well fitting surgeons hat for your new on the horizon career in the operating room!