NHS Scotland, one of the keystone healthcare providers in the UK, have recently set a wide variety of sustainability targets in an effort to mitigate waste and the intensive energy demands of healthcare. Medical garment production, management and design is an area in which design researchers can explore and offer solutions. This paper presents a series of co-design explorations to examine design alternatives to single-use theatre caps, the majority of which are currently disposed of routinely. Using a series of probes, major insights into how theatre cap design may be improved is presented.