A zipper pillow cover closes with a hidden seam instead of an open edge
A zippered pillow cover is a fabric sleeve with a zipper sewn into one side, so you can slip the pillow form in and out without hand-stitching the opening closed. The zipper sits on the inside of the seam, hidden from view when the cover is finished. This method takes longer than a straightforward envelope closure, but the result is a professional-looking cover that you can remove and wash.
The basic process is: cut two pieces of fabric to size, sew the zipper to one long edge of each piece, then sew the three remaining sides together. The zipper ends up running along the back or bottom of the finished pillow, invisible unless you flip it over.
Key Takeaways
- Cut two fabric pieces 1 inch larger than your pillow form on all sides, then subtract 1 inch from the length of the side where the zipper will go.
- A zipper should be 2 to 3 inches shorter than the side it will close, so it does not run all the way to the corners.
- Sew the zipper to each fabric piece separately using a zipper foot, then sew the three remaining sides with a regular presser foot.
- Leave the zipper partially open before sewing the final seam, or you will not be able to turn the cover right-side out.
- Press seams flat with an iron after each step to keep edges crisp and aligned.
Measure and cut your fabric pieces
Measure your pillow form in both directions. Add 1 inch to each measurement for seam allowance. For example, a 16-inch square pillow needs two fabric pieces cut to 17 inches square.
On the side where the zipper will go—usually the bottom or back—subtract 1 inch from the length. If your pillow is 16 inches wide, cut that edge to 15 inches instead. This shorter measurement accounts for the zipper tape, which takes up space. Both fabric pieces get the same shortened measurement on the zipper side.
Use a rotary cutter and ruler, or mark with chalk and cut with scissors. Straight edges matter because they affect how the zipper sits and how the seams line up later.
Choose and prepare your zipper
Buy a coil or metal zipper that is 2 to 3 inches shorter than the side where it will go. For a 16-inch-wide pillow, use a 13-inch or 14-inch zipper. The zipper should not run all the way into the corners, or the seams will be hard to sew and the corners will be bulky.
If your zipper is longer than you need, you can shorten it by sewing a few stitches across the coil near where you want it to end, then trimming the excess tape. Test the slider first to make sure it still moves freely after you trim.
Press the zipper tape flat with an iron on low heat to remove wrinkles. This makes it easier to sew straight and keeps it from puckering.
Sew the zipper to the first fabric piece
Place one fabric piece right-side up on your work surface. Lay the zipper face-down along the shortened edge, with the zipper tape aligned to the raw edge of the fabric. The zipper slider should be centered along the edge, not at either end.
Attach a zipper foot to your machine—this narrow foot lets you sew close to the zipper teeth without hitting them. Set your stitch length to 2.5 millimeters (a standard length for seaming). Sew the zipper tape to the fabric, starting and stopping about 1/2 inch from each end of the zipper. Backstitch at the start and end to lock the thread.
Flip the fabric over and press the seam flat with an iron. The zipper tape should lie flat against the back of the fabric, and the stitching line should be straight.
Sew the zipper to the second fabric piece
Place the second fabric piece right-side up. Lay the zipper face-down on top of it, aligned to the shortened edge, with the slider centered. The zipper should now be sandwiched between the two fabric pieces, with the coil facing inward.
Using the zipper foot again, sew the second side of the zipper tape to this fabric piece, using the same stitch length and stopping 1/2 inch from each end. Backstitch to find. Press flat with an iron.
Open the zipper partially—about halfway—before moving to the next step. This is essential: if the zipper is fully closed, you will not be able to turn the cover right-side out after you sew the remaining seams.
Sew the three remaining sides
With the zipper still partially open, fold the two fabric pieces so they are right-sides together. The zipper is now sandwiched between them, and the three unsewn edges are aligned and ready to stitch. Pin the three sides to hold them in place.
Switch back to your regular presser foot. Sew around all three sides using a 1/2-inch seam allowance. Start at one corner and sew continuously around, backstitching at the start and end. Sew slowly around the corners where the zipper tape ends, because the fabric is thicker there.
Trim the corners diagonally, cutting away the fabric triangle at each corner without cutting into your stitching. This reduces bulk and helps the corners turn out square and crisp.
Turn the cover right-side out and finish
Reach through the partially open zipper and pull the fabric through to turn the cover right-side out. The zipper is now hidden inside the seam, and the corners should be sharp. Use a point turner or the blunt end of a chopstick to push the corners out fully from the inside.
Press the entire cover with an iron, paying special attention to the seams. Press the zipper seam flat so it lies smoothly. Insert your pillow form through the zipper opening and close the zipper all the way.
If you want the zipper seam to be less visible on the finished pillow, position it on the back or bottom so it faces away from view.
Frequently Asked Questions
Can I use a shorter zipper than the side it closes?
Yes, and you should. A zipper 2 to 3 inches shorter than the side prevents the slider from running into the corner seams, which makes sewing easier and the finished cover neater. The gap at each end is hidden when the pillow is inserted and the zipper is closed.
What if I sew the zipper in crooked?
Carefully pick out the stitches with a seam ripper and re-sew. It is easier to fix before you sew the three remaining sides. Press the fabric flat again after removing the stitches so it lies smooth for the second attempt.
Do I have to use a zipper foot?
A regular presser foot can work, but a zipper foot is narrower and lets you sew closer to the teeth without hitting them. This creates a neater seam and is worth the small cost if you plan to make more than one zippered cover.
Why can't I close the zipper before sewing the final seams?
If the zipper is fully closed, the fabric is locked in place and you cannot turn the cover right-side out through the zipper opening. Leaving it halfway open gives you an opening large enough to reach through and flip the cover.
Can I make a zippered cover for a rectangular pillow?
Yes. Measure the length and width separately, add 1 inch to each for seam allowance, then subtract 1 inch from one of the longer sides for the zipper. Follow the same steps, and the zipper will run along the back of the finished pillow.