A zipper pillow cover is easier than you think
A zippered pillow cover lets you remove and wash the fabric without taking apart the whole pillow. You sew three sides of the cover closed, insert a zipper along the fourth side, and then slide the pillow form inside. The zipper sits on the back or bottom of the pillow where it is less visible. This method works for any pillow size and takes about an hour once you have your fabric and zipper ready.
The key difference from a regular sewn pillow is that you install the zipper before you close the final seam. You will sew the zipper to two fabric pieces, then sew those pieces to the rest of the cover. It sounds like extra steps, but the zipper goes in faster than hand-stitching a closing seam, and the result is much neater.
Key Takeaways
- Cut two fabric pieces the same size as your finished pillow, plus half an inch on all sides for seam allowance.
- The zipper should be one to two inches shorter than the width of your pillow so the ends stay hidden inside the seams.
- Sew the zipper to two separate fabric pieces first, then sew those pieces to the front and back panels of your cover.
- Leave the zipper partially open before you turn the cover right-side out, or you will not be able to flip it.
- Press all seams flat with an iron after sewing to make the pillow look finished and professional.
What you need before you start
Gather your fabric, zipper, thread, and basic sewing supplies. You will need two pieces of fabric cut to the size of your finished pillow plus half an inch on all four sides for seam allowance. If your pillow is 16 inches square, cut two pieces that are 17 inches square. Use a rotary cutter and ruler for straight edges, or mark your cutting lines with a pencil and cut with scissors.
Choose a zipper that is one to two inches shorter than the width of your pillow. A 16-inch pillow needs a 14-inch or 15-inch zipper. Longer zippers will poke out past the seams and look bulky. Buy a zipper made for the weight of your fabric—lightweight zippers for cotton quilting fabric, heavier zippers for canvas or upholstery fabric. Thread should match your fabric color or be a neutral shade like gray or tan.
Set up your sewing machine with a fresh needle and thread wound on both the top and bobbin. Test the machine on scrap fabric to make sure the tension is even and the stitches are straight. Have an iron and ironing board ready to press seams as you work.
Preparing the zipper panels
Cut two strips of fabric that will hold the zipper. These strips should be the full width of your pillow (plus seam allowance) and about three inches tall. If your pillow is 16 inches wide, cut two strips that are 17 inches wide and 3 inches tall. These will become the top and bottom edges of your pillow cover, with the zipper running between them.
Open the zipper all the way. Place one fabric strip right-side up on your sewing machine bed. Lay the zipper face-down on top of the strip, with the zipper teeth aligned along one long edge of the fabric. The zipper pull should point toward the left. Pin the zipper in place every inch or so, keeping the pins perpendicular to the zipper so they do not catch in the presser foot.
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 the edge where the zipper meets the fabric, using a straight stitch and a stitch length of 2.5 to 3.0 millimeters. Sew slowly and stop every few inches to lift the presser foot and check that the zipper is still aligned. When you reach the zipper pull, stop with the needle down, lift the presser foot, slide the pull out of the way, and keep sewing.
Flip the fabric strip over so the zipper is now face-up. Press the fabric flat with an iron, then fold the fabric edge over the zipper tape so it covers the stitching line. Pin this fold in place. Sew along the fold using a straight stitch, staying close to the edge. This second row of stitching holds the zipper tape down and makes the seam look finished.
Repeat this process with the second fabric strip on the other side of the zipper. When both strips are sewn, you will have a zipper sandwiched between two pieces of fabric, with stitching on both sides of the zipper.
Assembling the pillow cover
Lay out all four pieces of your pillow cover on a flat surface: the two zipper panels (sewn together with the zipper between them) and the two remaining fabric pieces that will be the front and back of the pillow. Open the zipper halfway—this is important and straightforward to forget. If the zipper is closed all the way, you will not be able to turn the cover right-side out later.
Place the front fabric piece right-side down on your work surface. Lay one of the zipper panels on top, right-side down, so the raw edges line up. Pin along this edge, placing pins every two inches. Sew with a straight stitch and a half-inch seam allowance. Press the seam flat with an iron.
Flip the cover over. Lay the back fabric piece right-side down on top, with raw edges aligned. Pin and sew along this edge the same way. Press this seam flat as well. Now you have a rectangle with the zipper running down the middle and the front and back panels on either side.
Fold the cover in half so the right sides face each other and the zipper is on the inside. Pin the two remaining raw edges together—these are the left and right sides of the pillow. Sew both of these edges with a half-inch seam allowance, using a straight stitch. Backstitch at the beginning and end of each seam to lock the thread. Press both seams flat.
Turning and finishing the cover
Reach through the open zipper and grab the fabric from the inside. Pull gently to turn the cover right-side out. The seams should now be hidden on the inside, and the fabric should look smooth on the outside. If a corner is still inside-out, use a blunt tool like a wooden spoon handle to gently push it out from the inside.
Press the entire cover with an iron, paying special attention to the seams and corners. Use a pressing cloth (a thin cotton cloth or even a tea towel) between the iron and your fabric to avoid shine marks. Press the edges where the zipper panels meet the front and back panels so they lie flat and crisp.
Slide your pillow form through the open zipper. Adjust the form so it sits evenly in all four corners, then close the zipper all the way. The cover is now complete and ready to use. When you need to wash it, straightforward open the zipper and remove the pillow form.
Common mistakes and how to avoid them
The zipper is crooked or puckered. This happens when the fabric shifts while you are sewing. Pin more frequently—every half inch instead of every inch—and sew slowly. If the zipper is already sewn crooked, use a seam ripper to remove the stitches and start over. Do not try to sew over crooked stitches.
The zipper pull gets caught in the presser foot. Stop sewing before the pull reaches the foot, lift the presser foot, slide the pull backward out of the way, lower the foot again, and keep sewing. Practice this motion on scrap fabric first so you know how it feels.
You cannot turn the cover right-side out. This means the zipper was closed when you tried to flip it. Unzip it halfway and try again. If the cover is already turned, you will need to open a seam, unzip the zipper, and re-sew the seam.
The corners are lumpy or the seams are uneven. Press every seam as soon as you finish sewing it, before you sew the next seam. Use an iron set to the temperature recommended for your fabric. Press from the back side of the fabric first, then flip and press the front. This flattens the thread and makes the seams lie smoothly.
Choosing the right zipper for your pillow
Zippers come in different weights and materials. A coil zipper has a spiral of nylon thread instead of metal teeth and works well for lightweight fabrics like cotton or linen. A metal zipper has brass or aluminum teeth and is stronger, making it better for heavier fabrics like canvas or upholstery cloth. Both types are available at fabric stores and online.
The length matters more than the type. Measure the width of your finished pillow and subtract one to two inches. A 16-inch pillow needs a 14-inch or 15-inch zipper. If you cannot find the exact length, buy the next size down rather than up. A zipper that is too long will stick out past the seams and look unfinished.
Color does not have to match exactly, but it should not stand out. A dark zipper on a light pillow will be visible when the cover is open. If you cannot find a matching color, choose a neutral shade like black, white, gray, or tan that works with most fabrics.
Frequently Asked Questions
Can I use a regular foot instead of a zipper foot?
A regular presser foot is too wide and will bump into the zipper teeth, making it hard to sew a straight line close to the zipper. A zipper foot costs five to ten dollars and attaches to any sewing machine. It is worth buying if you plan to sew more than one zippered pillow.
What happens if my zipper is too long?
The ends will poke out past the seams and look bulky. If you realize this after sewing, you can trim the zipper tape with scissors, but do not cut the teeth themselves. Cut only the woven tape on the ends. Seal the cut edge with a small amount of clear nail polish or fabric glue to keep it from fraying.
Do I have to sew the zipper on both sides?
Sewing on both sides makes the seam look finished and keeps the zipper tape from shifting. If you sew only one side, the zipper will be visible from the back and may come loose over time. The second row of stitching takes only a few extra minutes and makes a big difference in how professional the pillow looks.
Can I use this method for a rectangular pillow?
Yes. The steps are exactly the same. Measure your pillow length and width, add half an inch on all sides for seam allowance, and cut your fabric pieces to that size. The zipper should be one to two inches shorter than the width of the pillow, not the length.
How do I fix a zipper that gets stuck?
Stop pulling and do not force it. Rub a pencil along both sides of the zipper teeth—the graphite acts as a lubricant. Gently wiggle the pull back and forth a few times, then try sliding it again. If the zipper is still stuck, the fabric may be caught in the teeth. Lift the fabric gently and try again.