The basic method: measure, cut, sew three sides, turn, stuff, close

A cushion cover is a fabric rectangle sewn on three sides, turned inside-out to hide the seams, stuffed with filling, and then sewn shut on the fourth side. The whole process takes two to four hours for a beginner, depending on cushion size and whether you use a sewing machine or hand-sew. You need fabric, thread, a needle or machine, scissors, pins, and a measuring tape. The filling — polyester fiberfill, down, or foam — goes in after the cover is mostly done.

The reason you sew three sides first, turn it, and then stuff it is that turning the cover inside-out hides all the raw seams inside. If you stuffed it first and then sewed, the seams would show on the outside. This method works for square, rectangular, and round cushions, though the cutting and pinning steps change slightly for round ones.

Key Takeaways

  • Measure your cushion form or the space you are filling, add half an inch on all sides for seam allowance, and cut two identical fabric pieces to that size.
  • Pin the two pieces together with the right sides (the pretty sides) facing each other, then sew three complete sides using a straight stitch, leaving one side open for stuffing.
  • Turn the cover inside-out through the opening so the seams are now hidden inside, then press the edges flat with an iron or your fingers.
  • Stuff the cover firmly but not so tight that seams strain, then fold the raw edges of the opening inward and sew it shut by hand or machine.
  • A sewing machine is faster and produces stronger seams, but hand-sewing with a needle and thread works just as well if you use small, even stitches.

Measuring and cutting your fabric pieces

Start by measuring the cushion form or the finished size you want. If you are covering an existing cushion, measure its width and height. If you are making a new one, decide the size first — a standard throw pillow is 16 by 16 inches, but any size works.

Add half an inch to all sides for the seam allowance. This is the space between the edge of the fabric and the line where you actually sew. A half-inch seam allowance is standard and leaves enough room to sew without the thread pulling through the fabric edge. So a 16-by-16 cushion needs two fabric pieces cut to 17 by 17 inches.

Lay your fabric flat on a clean surface. Use a measuring tape and a pencil or fabric marker to mark the cutting lines. Cut both pieces to the exact same size using sharp fabric scissors. Uneven pieces will make the finished cover lopsided. If your fabric has a pattern or direction (like stripes or a nap), make sure both pieces face the same way before you cut.

Pinning and sewing three sides

Place the two fabric pieces on top of each other with the right sides (the pretty, finished sides) facing inward toward each other. The wrong sides (the back or duller side) should face outward. This is the key step: when you sew and then turn the cover inside-out, the seams will be hidden inside and the right sides will show on the outside.

Pin the two pieces together around all four edges, placing pins every two to three inches. The pins hold the fabric steady while you sew. Leave one full side completely unpinned — this is your opening for stuffing. A common choice is to leave one of the shorter sides open on a rectangular cushion, or any side on a square one.

Sew along three sides using a straight stitch, staying exactly half an inch from the edge. If you are using a sewing machine, set it to a medium stitch length (around 2.5 on most machines) and sew slowly so the fabric stays straight. If you are hand-sewing, use a needle threaded with thread that matches your fabric, and make small, even stitches about an eighth of an inch apart. Backstitch (sew backward over the same spot) at the beginning and end of each seam to lock the thread in place.

Sew all the way to the corner on each side. At the corners, stop with the needle down, lift the presser foot (if using a machine), pivot the fabric 90 degrees, lower the presser foot, and continue sewing the next side. This creates a sharp corner instead of a rounded one.

Turning the cover right-side-out and pressing

Once you have sewn three sides, you have a fabric envelope with one open side. Reach through the opening and grab the fabric from the inside. Pull gently and steadily until the whole cover turns inside-out. The right sides are now facing outward, and all the seams are hidden inside. This step takes a minute or two and feels strange the first time, but it works every time.

Use your fingers to push the corners out so they are sharp and square, not rounded. If the corners are still rounded after you push them, use a chopstick, the blunt end of a pencil, or a corner tool (a small plastic stick sold in fabric stores) to poke them out from the inside.

Press the cover flat using an iron on a low to medium setting, or straightforward run your fingers along all the seams to flatten them. Pay special attention to the edges around the opening — flatten them as much as possible so the final seam lies flat when you close it.

Stuffing the cushion cover

Fill the cover with polyester fiberfill, down, or foam pieces until it feels full but not rock-hard. Overstuffing makes the seams strain and can cause them to split. Understuffing makes the cushion look flat and sad. The right amount feels firm when you squeeze it, with just a little give. For a 16-by-16 cushion, you will use roughly 16 ounces of fiberfill, but the exact amount depends on how densely you pack it.

If you are using a foam insert instead of loose filling, slide it in through the opening. Foam inserts are pre-cut to standard sizes and do not require measuring.

Closing the opening by hand or machine

Fold the raw fabric edges of the opening inward by half an inch, so the fold lines up with where you sewed the other three sides. Pin the opening shut. The fold should hide the raw edges inside, just like the rest of the seams.

You can close this opening either by machine or by hand. By machine, sew along the fold using the same straight stitch you used for the other sides, staying as close to the edge as possible. By hand, use a ladder stitch (also called an invisible stitch or slip stitch), which hides the thread inside the fold and makes the seam nearly invisible. To ladder stitch, bring the needle out through the fold, cross over to the opposite side, go through the fold there, and then travel inside the fold for about half an inch before coming back out. Repeat along the entire opening. The thread stays hidden inside the fold the whole time.

Whichever method you choose, sew all the way to both corners so the opening is completely closed and the stuffing cannot come out.

Hand-sewing versus machine-sewing

A sewing machine is faster — you can sew three sides in 15 to 20 minutes. Machine seams are also stronger and more even, which matters if the cushion will get heavy use or washing. Most home machines handle cushion-weight cotton and linen easily.

Hand-sewing takes longer, roughly 45 minutes to an hour for three sides, but requires no equipment beyond a needle and thread. Hand seams are just as strong if you use small, tight stitches and backstitch regularly. Hand-sewing is also quieter and gives you more control if your fabric is delicate, slippery, or has a thick nap.

Many people machine-sew the three main sides and then hand-sew the closing seam, since the closing is shorter and hand-sewing it makes the seam nearly invisible. This is a good middle ground if you have access to a machine.

Common mistakes and how to avoid them

The most common mistake is sewing with the wrong sides facing outward. This leaves the seams visible on the outside of the finished cushion. The fix is straightforward: always check before you start sewing that the right (pretty) sides are facing each other and the wrong (dull) sides are facing out.

The second mistake is leaving the opening too small. If the opening is less than 6 inches long, it is hard to turn the cover and stuff it without tearing the fabric. Leave at least one full side open, or cut a longer opening in the middle of one side if you prefer.

The third mistake is sewing the opening shut before the cover is fully stuffed, or overstuffing so much that the seams strain. Stuff the cover completely before you close it, and make sure it feels firm but not hard.

Uneven stitches or skipped stitches can weaken the seams. If you are hand-sewing, keep your stitches small and even. If you are machine-sewing, check that your thread is threaded correctly and your needle is not bent or dull.

Frequently Asked Questions

What kind of fabric works best for cushion covers?

Cotton, linen, and cotton blends are easiest to sew and wear well. Avoid stretchy fabrics like knits or spandex unless you have a ballpoint needle, which prevents runs. Velvet and corduroy are beautiful but slippery — pin them carefully and sew slowly. Avoid very thin fabrics that fray easily unless you finish the seams with a zigzag stitch or pinking shears.

Can I machine-wash a cushion cover I sewed myself?

Yes, if you used washable fabric and thread. Wash in cold water on a gentle cycle, and air-dry to avoid shrinking. Remove the cushion form first if it is not washable. If you used a zipper or hand-stitched seams, check them after the first wash to make sure they held.

What is the difference between a seam allowance and a hem?

A seam allowance is the fabric between the edge and the stitch line — it is hidden inside after you turn the cover. A hem is a fold of fabric on the outside edge that you sew down to finish the edge. Cushion covers use seam allowances, not hems.

Do I need a sewing machine to make a cushion cover?

No. Hand-sewing works perfectly well and produces the same result, just more slowly. Use a needle, thread, and small, even stitches. A machine is faster and produces very straight seams, but it is not required.

What should I do if my seams are crooked or uneven?

Crooked seams on the three main sides will show after you turn the cover, so if they are very bad, you can unpick them (cut the thread and pull it out), adjust the fabric, and sew again. For the closing seam, minor unevenness does not matter much since it is on the inside. If you are hand-sewing the closing, use a ladder stitch to hide the thread completely.