What You Need Before You Start
A zippered cushion cover requires fabric, a zipper, thread, and basic sewing tools—nothing you cannot find at a fabric store or online. The zipper is the one part that matters most: buy one that is 2 to 3 inches shorter than the side of your finished cushion. If your cushion is 16 inches square, a 13- or 14-inch zipper works well. A shorter zipper is easier to sew in and leaves room for seam allowance on both ends.
Gather fabric (two pieces cut to the same size), a zipper in a matching or contrasting color, thread that matches your fabric, a sewing machine, scissors, pins, a measuring tape, and a seam ripper for mistakes. You will also need an iron to press seams flat as you work—this makes the final cover look professional and helps the zipper sit evenly.
Key Takeaways
- Cut two fabric pieces to the exact size you want your finished cover to be, plus half an inch on all sides for seam allowance.
- Sew the zipper to one long edge of each fabric piece before joining the sides, using a zipper foot on your machine.
- After the zipper is attached, sew the remaining three sides closed, leaving a small opening at one corner to turn the cover right-side out.
- Turn the cover inside out through that opening, press it flat with an iron, and hand-stitch the opening closed.
- Insert your cushion through the zipper and close it—the cover is now complete and removable for washing.
Cutting Your Fabric to the Right Size
Measure your cushion form in both directions. If it is 16 inches by 16 inches, cut your two fabric pieces to 17 inches by 17 inches. That extra half inch on all sides becomes your seam allowance—the space between the edge of the fabric and the line where your needle actually stitches. Without seam allowance, your finished cover will be too small.
Use a ruler or measuring tape and mark your cutting lines with a fabric pencil or chalk before you cut. Cut both pieces exactly the same size. Lay them on top of each other and trim any uneven edges so they match perfectly. Uneven pieces will cause the zipper to sit crooked or the sides to pucker when you sew them together.
Preparing the Zipper and Attaching It to the First Piece
Place one fabric piece right-side up on your work surface. Lay the zipper face-down along one edge, with the zipper teeth pointing toward the fabric and the zipper tape extending into the seam allowance. The zipper should sit about half an inch from the edge of the fabric. Pin it in place along that edge.
Install a zipper foot on your sewing machine—this is a special presser foot that lets you stitch close to the zipper teeth without hitting them. Sew along the pinned edge, stitching through the fabric and the zipper tape. Stitch about a quarter inch from the zipper teeth. Remove the pins as you go. Press this seam flat with your iron when you are done.
Now place the second fabric piece right-side down on top of the first piece, so the two pieces face each other with the zipper sandwiched between them. Pin the second piece along the same edge. Sew this seam the same way—using the zipper foot, stitching a quarter inch from the teeth. Press this seam flat as well. You now have both fabric pieces attached to the zipper, one on each side.
Sewing the Remaining Three Sides
Open the zipper halfway. This is important: if you sew all the way around with the zipper closed, you will not be able to turn the cover right-side out later. With the zipper open, you have an opening to work through.
Switch back to your regular presser foot. Sew the three remaining sides of the cushion cover, starting at one corner and working around. Use a half-inch seam allowance on all three sides to match the seams where the zipper is attached. At one corner of the third side, stop about 3 inches before you reach the end. Backstitch to lock your thread, then cut it. Leave that 3-inch opening—you will use it to turn the cover right-side out.
Trim the corners of the fabric at a diagonal, cutting away the excess fabric at each corner without cutting into your stitching. This step keeps the corners from bunching up when you turn the cover right-side out. Press all four seams flat with your iron.
Turning the Cover Right-Side Out and Closing the Opening
Reach through the 3-inch opening and grab the fabric on the opposite side. Pull gently and steadily until the entire cover turns inside out through that opening. Use a blunt tool like a chopstick or the handle of a wooden spoon to push the corners out from the inside so they are sharp and square, not rounded.
Press the entire cover flat with your iron, paying special attention to the seams and the opening you just turned through. Fold the raw edges of the opening inward by half an inch and press them. Pin the opening closed.
Thread a needle with thread that matches your fabric. Use a ladder stitch (also called an invisible stitch) to close the opening by hand. Bring the needle up through one folded edge, across through the fold of the opposite edge, and back down through the first edge, moving forward a quarter inch each time. The stitches will be hidden inside the fold. When the opening is closed, press the seam one more time.
Inserting the Cushion and Using Your Cover
Open the zipper fully. Slide your cushion form through the opening. Close the zipper. The cover is now complete and ready to use. Because the zipper runs along one edge, you can unzip it anytime to remove the cover for washing or to replace the cushion form.
If the cover feels tight around the cushion, you cut the fabric pieces too small. If it is loose and wrinkled, the pieces were too large. Either way, you now know the adjustment to make for your next cover. Most people get the fit right on the second try.
Troubleshooting Common Problems
If your zipper puckers or sits crooked, you likely pinned it unevenly or sewed at an angle. Use a seam ripper to remove the stitches, repin the zipper straight, and sew again. Take your time on this step—a straight zipper makes the whole cover look better.
If the corners are rounded instead of square after you turn the cover right-side out, you did not trim the corner fabric away before turning. You can still push them out with a chopstick, but trimming first makes this easier. If the opening does not close neatly, you may have left it too large or the edges are not folded evenly. Refold them, press again, and use smaller stitches on the ladder stitch.
If the cover is bunching or puckering along the sides after you insert the cushion, the seams may not be straight or the fabric pieces were not cut to exactly the same size. Check that both pieces were truly identical before you sewed them together next time.
Frequently Asked Questions
Can I use a different type of zipper?
Yes. Coil zippers (the most common type) work well for cushion covers. Metal zippers are more durable but heavier. Invisible zippers blend into the seam but are harder to sew. Stick with a coil zipper for your first cover—it is the easiest to work with and the most forgiving if your stitching is not perfect.
What if I do not have a zipper foot?
A zipper foot makes sewing close to the teeth much easier, but you can sew a zipper without one if you move your needle position to the right or left on your machine. It is slower and riskier—you might hit the teeth and break your needle. A zipper foot costs five to ten dollars and is worth buying if you plan to make more than one cover.
Can I sew the zipper on a different side?
Yes. The zipper can go on any of the four sides. Some people prefer it on the bottom so it is less visible when the cushion is on a chair or couch. Just make sure you open it halfway before sewing the other three sides, or you will not be able to turn the cover right-side out.
How do I wash a zippered cushion cover?
Unzip the cover fully and remove the cushion form. Wash the cover in cool water on a gentle cycle, or hand-wash it if the fabric is delicate. Close the zipper before washing so it does not snag other items. Dry on low heat or air-dry to avoid shrinking.
What thread should I use?
Use all-purpose polyester thread in a color that matches your fabric. If your fabric is patterned or multicolored, choose a thread that matches the dominant color. Thread that matches is nearly invisible in the seams; contrasting thread shows every stitch.