Surgical caps are meant not only for doctors and nurses, but for patients as well. While they are an essential item, surgical caps can be expensive to buy in stores and a surgical cap pattern can cost quite a bit, too. Fortunately, it is easy to make your own bouffant surgical cap without a pattern. As long as you have basic sewing skills, you can make your own surgical caps for doctors, nurses, patients or even Halloween costumes.
Cut out a circle of fabric that is 24 inches in diameter. Fold over the edges of the fabric 1/2 an inch and iron.
Hem the fabric circle all the way around, tucking the raw edges under as you sew. Leave an opening of about 1 inch.
Measure the circumference of your head from your forehead, around the top of your face, under your ears and to the nape of your neck. Cut out a piece of elastic that meets this measurement exactly.
Thread the elastic through the hem of the fabric through the 1 inch opening, gathering the fabric as you go. Sew the two ends of the elastic together and hand sew the opening in the hem closed.