A zipper makes your cushion cover removable and washable
A zippered cushion cover is sewn almost the same way as a regular cover, but the zipper replaces one of the seams. Instead of sewing the opening closed, you insert a zipper into that seam so you can open and close the cover to remove the cushion pad for washing. The zipper sits hidden inside the seam, so it does not show on the finished cover.
The basic steps are: cut two pieces of fabric to size, sew three sides closed, insert the zipper into the fourth side, then sew the zipper in place. If you have sewn a basic cushion cover before, you already know how to do most of this. The only new skill is attaching the zipper, which is straightforward once you understand the order of the steps.
Key Takeaways
- Cut two fabric pieces the same size as your cushion pad, plus half an inch on all sides for seam allowance.
- Sew three sides of the cover closed with a straight stitch, leaving the fourth side open for the zipper.
- Pin the zipper face-down along the open edge, then sew it in place using a zipper foot on your machine.
- Turn the cover right-side out through the zipper opening, insert your cushion pad, and zip it closed.
- A 16-inch or 18-inch zipper works for most cushions; measure your opening to be sure before you buy.
Measure your cushion and choose the right zipper length
Measure the width of the side where you plan to put the zipper. If your cushion is 16 inches square, that side is 16 inches long. Buy a zipper that is slightly shorter than that measurement—usually 14 inches for a 16-inch cushion, or 16 inches for an 18-inch cushion. The zipper does not need to run the entire length of the seam; it stops about an inch from each corner.
Zipper length matters because a zipper that is too long will stick out past the seam and be difficult to sew. A zipper that is too short will not open far enough to remove the cushion pad easily. When in doubt, go slightly shorter rather than longer. You can always open the zipper partway to slide the pad in and out.
Buy a coil zipper or metal zipper in a color that matches your fabric, or choose a neutral color like black or white. Avoid zippers marketed for bags or jackets—those are often too stiff for cushion covers. A standard dress or home-décor zipper works well.
Cut and prepare your fabric pieces
Cut two pieces of fabric to the size of your finished cushion, plus half an inch on all sides. If your cushion pad is 16 inches square, cut two 17-inch squares. The extra half inch on each side is your seam allowance—the space where the needle goes when you sew.
Place the two fabric pieces with the right sides facing each other (the pretty sides touching, the wrong sides facing out). Pin around all four edges to hold them in place while you sew. This is the same setup you would use for a cover without a zipper.
Sew three sides closed, leaving one side open
Using a straight stitch on your sewing machine, sew along three sides of the fabric, staying half an inch from the edge. Use a regular presser foot (not the zipper foot yet). Sew slowly and keep the line straight. Backstitch at the start and end of each seam to lock the thread.
Leave the fourth side completely open—do not sew it at all. This is where the zipper will go. When you finish the third side, cut the thread, remove the pins, and set the cover aside.
Insert and pin the zipper along the open edge
Lay the cover flat with the open side facing you. The fabric should still be inside-out (wrong sides facing out). Open the zipper all the way and lay it face-down along the open edge, with the zipper teeth pointing toward the fabric and the zipper pull facing away from you.
Align the top edge of the zipper tape (the flat woven part on either side of the teeth) with the raw edge of the fabric. Pin the zipper in place along both sides, using pins every inch or so. The zipper should lie flat and straight, not twisted or bunched.
If the zipper is shorter than the opening, center it so there is equal space on both sides. You will sew the remaining fabric edges closed after the zipper is attached.
Sew the zipper in place with a zipper foot
Switch to a zipper foot on your sewing machine. This foot is narrower than a regular presser foot and sits to one side of the needle, so you can sew close to the zipper teeth without hitting them. If you do not have a zipper foot, ask at a fabric store—they cost between five and fifteen dollars and fit most machines.
Sew along one side of the zipper, staying about a quarter inch from the zipper teeth. Sew slowly and keep the line straight. When you reach the end, backstitch to lock the thread. Remove the pins as you go.
Flip the cover over and sew along the other side of the zipper the same way. Both sides of the zipper tape should now be sewn to the fabric. Close the zipper partway to make sure it moves smoothly before you continue.
Close the remaining fabric edges
Open the zipper all the way. You now have two gaps of unsewn fabric on either side of the zipper—one at each corner. Fold the raw edges of the fabric inward by half an inch and pin them closed. Sew these two short seams with a straight stitch, backstitching at the start and end.
When you finish, the entire opening should be closed except for the zipper itself. The zipper teeth are now enclosed inside the seam and hidden from view.
Turn the cover right-side out and insert the cushion
Open the zipper about halfway. Reach through the opening and grab the fabric from the inside, then pull the whole cover through the zipper opening to turn it right-side out. This takes a little wiggling, but the zipper opening is large enough to fit a cushion pad through, so it is large enough for this step.
Once the cover is right-side out, poke the corners out with a blunt tool (a chopstick or the eraser end of a pencil works well) so they are sharp and square. Insert your cushion pad through the zipper opening, position it so the corners sit in the corners of the cover, and zip the cover closed.
Frequently Asked Questions
Can I use a longer zipper than my opening?
Yes, but it is awkward. A zipper longer than the seam will bunch up and be hard to sew straight. It is better to buy the correct length. If you already have a long zipper, you can shorten it by sewing across the teeth near one end with a tight zigzag stitch, then cutting off the excess.
What if my zipper gets stuck while I am sewing?
Stop and close the zipper partway, then continue sewing. A zipper that is fully open can catch on the presser foot. Closing it a few inches ahead of where you are sewing prevents this. Make sure the zipper pull is not in the way of the foot before you start.
Do I need a special foot to sew a zipper?
A zipper foot makes the job much easier and costs very little, but you can sew a zipper with a regular presser foot if you move the needle position to the left or right. Check your machine manual for how to do this. A zipper foot is still worth buying if you plan to make more than one cushion.
Can I put the zipper on a different side?
Yes. The zipper can go on any of the four sides. Many people put it on the bottom so it is less visible when the cushion is on a chair or sofa. Choose whichever side is easiest for you to reach when you need to remove the pad for washing.
What if the zipper opening is too small to fit the cushion pad through?
Open the zipper all the way and gently work the cushion pad through, folding it if needed. If the pad is much larger than the opening, you may have cut the cover too small. For future covers, add an extra inch to your measurements so the opening is more generous.