A zipper pillow cover is easier to make than you might think

A zippered pillow cover is a fabric sleeve with a zipper sewn into one seam, so you can slide the pillow in and out without hand-stitching it closed. The zipper goes on the back or bottom of the cover, hidden from view. You sew three sides of the cover completely, insert the zipper into the fourth side, then sew the zipper in place. The whole project takes about an hour once you have your fabric and zipper, and you only need a sewing machine, thread, scissors, and a measuring tape.

The process is straightforward: cut two matching pieces of fabric, sew three sides together, pin the zipper along the open edge, sew it in place with a zipper foot, close the final gaps, and turn the cover right-side out. Even if you have never sewn a zipper before, the steps are the same every time, and mistakes are straightforward to fix by removing stitches and resewing.

Key Takeaways

  • Cut two pieces of fabric to the same size—usually 1 to 2 inches larger than your pillow on all sides—and add a half-inch seam allowance on every edge.
  • Sew three sides of the cover with a standard straight stitch, leaving one side open for the zipper.
  • Pin the zipper face-down along the open edge, with the zipper teeth aligned to your seam line, then sew it in place with a zipper foot.
  • Sew the fourth side closed, stitching right next to the zipper to seal the opening, then turn the cover right-side out and insert your pillow.
  • A 16-inch or 18-inch zipper works for most standard pillows; measure your pillow width to choose the right length.

Measure your pillow and cut the fabric

Start by measuring your pillow's width and height. If your pillow is 16 inches wide by 16 inches tall, cut two pieces of fabric that are 17 inches by 17 inches—that adds a half-inch seam allowance on all four sides. If you want a looser fit, add 1 to 2 inches instead. Write these measurements down so you do not cut one piece too small by accident.

Lay one piece of fabric on a flat surface, place your ruler or measuring tape along one edge, and mark the corners with a pencil or fabric pen. Cut straight lines with sharp fabric scissors or a rotary cutter. Cut both pieces to exactly the same size. If the pieces are different sizes, the cover will not close evenly, and the zipper will pull to one side when you try to open and close it.

Choose a zipper that matches your pillow width

Buy a coil zipper or metal zipper that is 1 to 2 inches shorter than the width of your pillow. For a 16-inch pillow, a 14-inch or 16-inch zipper works well. Coil zippers are easier to sew by hand if you need to adjust them, while metal zippers are more durable. Both work in a sewing machine without any special settings.

If you cannot find a zipper in the exact length you need, buy one that is slightly longer—you can sew past the zipper stop at the end, and the extra length will not show once the cover is turned right-side out. Do not buy a zipper that is much shorter than your pillow width, or the opening will be too small to insert the pillow comfortably. Check the zipper length on the package before you buy it.

Sew three sides of the cover closed

Place the two fabric pieces with the right sides (the pretty sides) facing each other. Pin along three edges, leaving one long edge unpinned—this is where the zipper will go. Set your sewing machine to a straight stitch with a standard stitch length (usually 2.5 millimeters).

Sew along the three pinned sides, starting a half-inch from the corner and stopping a half-inch before the next corner. Backstitch at the start and end of each seam to lock the thread. Remove the pins as you sew. When you finish the three sides, you should have one long open edge and three closed seams. The fabric is still inside-out at this point—the right sides are facing each other, and the seams are on the outside.

Pin and sew the zipper into the open edge

Lay the cover flat with the open edge facing you. Unzip the zipper completely and lay it face-down along the open edge, with the zipper teeth aligned to your half-inch seam line. The zipper pull should point toward one corner. Pin the zipper in place every 2 to 3 inches, pinning through the fabric and the zipper tape (the flat fabric edges on either side of the teeth).

Attach a zipper foot to your sewing machine—this is a special presser foot that lets you sew close to the zipper teeth without hitting them. Sew along one side of the zipper, staying as close to the teeth as possible without stitching through them. Backstitch at the start and end. Flip the cover over, reattach the zipper foot, and sew along the other side of the zipper in the same way. Both sides of the zipper tape should now be sewn to the fabric.

Close the fourth side and turn the cover right-side out

After both sides of the zipper are sewn, you still have a small gap on either side of the zipper where the seam line meets the zipper tape. Sew these gaps closed by stitching right next to the zipper, from the edge of the zipper tape to the corner of the fabric on each side. This seals the opening completely and prevents the pillow from shifting inside the cover.

Reach inside the cover through the open zipper and grab a corner of the fabric. Pull the cover inside-out through the zipper opening. The right sides of the fabric are now facing outward, and the seams are hidden inside. Press the cover with an iron on low heat to flatten the seams, especially around the zipper. Open the zipper halfway, slide your pillow in, and zip it closed.

Troubleshooting common zipper problems

If the zipper is puckered or wavy after sewing, the fabric was not pinned evenly. You can remove the stitches with a seam ripper, repin the zipper, and sew again. If the zipper foot is hitting the zipper teeth and breaking your needle, move the needle position one notch to the left or right using your machine's needle position button. Most machines have a button or dial labeled with left and right arrows.

If the zipper is too long and sticks out past the seam, trim the excess zipper tape with scissors after sewing, but leave at least a quarter-inch of tape beyond the stitching so it does not unravel. If the zipper is too short and does not reach both corners, you will need to buy a longer zipper and start over—there is no way to extend a zipper once it is sewn in. Save the short zipper for a smaller project like a pouch or cushion cover.

Frequently Asked Questions

Can I use an invisible zipper instead of a regular zipper?

Yes, but it requires a special invisible zipper foot and more careful pinning. An invisible zipper sits inside the seam so the teeth do not show at all. The process is the same, but you sew closer to the zipper coil, and the stitching line is harder to see. Start with a regular zipper if this is your first cover.

What if I sew the zipper in upside down?

If the zipper pull is on the inside of the cover instead of the outside, you can still use it—just reach in through the opening and pull the zipper closed from inside. It is not ideal, but it works. To avoid this, mark which side is the front of your cover before you start sewing.

Do I need a special presser foot to sew a zipper?

A zipper foot is not required, but it makes sewing much easier because it lets you stitch closer to the teeth without breaking your needle. Most sewing machines come with a zipper foot, or you can buy one for ten to fifteen dollars. Without one, you will have to sew farther from the teeth, leaving a gap between the stitching and the zipper.

Can I wash a pillow cover with a zipper?

Yes. Close the zipper before washing, and wash in cold water on a gentle cycle. Dry on low heat or hang to dry. The zipper will not damage the washing machine, and washing will not damage the zipper unless you use very hot water or a high dryer temperature.