Sew Up a Recycled Green Hat

Craft & Design Home

In honor of the launch of the new 100% recyclable DASANI PlantBottle, made from a blend of up to 30% plant-based materials, DASANI has partnered up with founder/designer Erica Domesek to develop a limited edition Green Hat. The materials in this project are made from re-used and recycled materials to promote the importance of recycling, whether its plastic bottles, cans or household items. Enjoy this great project as we celebrate Earth Day next week!

Recycled Green Hat

By Erica Domesek


Repurposed cotton sweatpants
cut from a zippered sweatshirt, or buy a new one at a fabric/trimming store
Scissors fabric scissors or utility scissors work best
Needle and thread
match your thread to the Cap’s color
Straight pins
Thick rubber band
Fabric tape measurer


Dasaniplantbottle Step1
Step 1: Use cotton jersey sweatpants (more experienced sewers can try tee shirts or sweatshirts, however these may require a higher level of sewing ability to achieve desired fit).
Dasaniplantbottle Step2
Step 2: Cut one leg off pant at the widest point, which will form a tube base for the Green Hat.

Dasaniplantbottle Step3
Step 3: Measure your head’s circumference. This will help you size the opening for your cap. Cut the pant leg at the point where it is one inch wider than your head’s circumference. Re-cut if necessary to the proper size.
Dasaniplantbottle Step4
Step 4: Trim the pants tube to approximately 12″ in length. 

Dasaniplantbottle Step5
Step 5: Flip the tube inside out. 

Dasaniplantbottle Step6
Step 6: Gather the fabric at the tube’s narrower end.

Dasaniplantbottle Step7
Step 7: Wrap the thick rubber band around the narrow end several times until it’s tight and secure. For a slouchier Green Hat gather more towards the narrow end. For a hat with not as much slouch, gather closer to the wider opening.

Dasaniplantbottle Step8
Step 8: Trim the excess material just above rubber band.
Step 9: Turn the cap right side out.
Dasaniplantbottle Step10
Step 10: Use needle and thread to sew button on the top of the hat.

Dasaniplantbottle Step11
Step 11: Use a zipper to adorn the circumference of the green cap 3 inches from the bottom. Use only half of the zipper, with the zipper teeth facing up. Secure with straight pins around the hat and use a needle and thread to sew it around the outside. While sewing the zipper, use one hand to pull fabric slightly, so the zipper will stretch with the fabric when stretched onto head.
Dasani Erica Domesek Main
Step 12: Get creative with other household items and decorative trim, embellishments, and accents for your Green Hat!
About the Author:
Erica Domesek is a distinguished design and style expert and founder of the innovative designer DIY brand “PS-I Made This….“. Erica’s creative motto, “I see it, I like it, I make it,” reflects the belief that one can find inspiration anywhere and transform what one sees into something fabulous to wear, use or look at.

2 thoughts on “Sew Up a Recycled Green Hat

  1. Lolo says:

    Lovely tutorial! Thank you so much for sharing. I will try to make one for my daughter.
    Lolo :-)

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