The Basic Method: Two Fabric Pieces and a Seam

A pillow cover is two rectangles of fabric sewn together on three sides, then turned right-side out and stuffed. You sew the fourth side closed by hand or machine. The whole project takes one to two hours for a beginner, and you need only a needle, thread, scissors, and fabric — a sewing machine makes it faster but is not required.

Start by measuring your pillow insert or the pillow you want to cover. Add one inch to both the length and width to account for the seam allowance (the fabric between the edge and the stitching line). Cut two rectangles to that size. Place them with the right sides facing each other — the sides you want to show should be touching, not facing out. Pin around all four edges to hold them in place.

Sew three complete sides with a half-inch seam allowance, using either a sewing machine set to a straight stitch or a needle and thread with a running stitch. Leave one side completely open. Trim the corners at a 45-degree angle to reduce bulk when you turn the cover right-side out, but do not cut into the stitching itself.

Key Takeaways

  • Cut two fabric rectangles one inch larger than your pillow insert in both directions to leave room for seams.
  • Sew three sides with right sides facing each other, leaving one side open for turning and stuffing.
  • Turn the cover right-side out through the opening, then insert your pillow and close the fourth side by hand or machine.
  • A basic cover takes one to two hours and requires only fabric, thread, and a needle or sewing machine.
  • Trim corners before turning to reduce bulk, and use a ladder stitch for an invisible hand-sewn seam on the opening.

Turning and Stuffing the Cover

Once you have sewn three sides, reach into the opening and grab the fabric at one corner from the inside. Pull gently until that corner pops through the opening and the cover begins to turn right-side out. Keep pulling and working the fabric through until the entire cover is reversed and the seams are now on the inside where they belong.

Push the corners out fully using a blunt tool — a chopstick, a wooden spoon handle, or even a closed pen works well. This makes the corners sharp and square instead of rounded. Insert your pillow insert through the opening, or if you are stuffing with loose fiberfill, add it gradually and distribute it evenly before the opening gets too small to work with.

Closing the Fourth Side

You have two options: sew it closed by machine, or sew it by hand with a ladder stitch that is nearly invisible. For a machine seam, fold the raw edges inward by half an inch on both sides of the opening, pin them, and sew along the fold line. This creates a seam that matches the other three sides.

For a hand-sewn ladder stitch, thread a needle and knot the end. Bring the needle up through the fold of fabric on one side of the opening, then across into the fold on the opposite side. Move the needle forward inside the fold for about a quarter inch, then back out and across to the first side again. Repeat this pattern — the thread runs inside the fold and is hidden from view. After every inch or so, pull the thread snug to close the gap. Knot off inside the fold when you reach the end.

Fabric Choices and Preparation

Cotton quilting fabric, cotton sateen, linen, and cotton blends are all good choices for pillow covers. Avoid stretchy fabrics like jersey or knits unless you have experience with them — they slip under the needle and are harder to control. Flannel, corduroy, and canvas work but are thicker and require a stronger needle or machine.

Before you cut, wash and dry your fabric if you plan to wash the finished pillow cover. Fabric shrinks in the wash, and if you do not pre-shrink it, your cover may be too small after the first cleaning. Check the fabric bolt or ask the store clerk whether the fabric needs special care — some prints bleed color, and some weaves require gentle washing.

Sewing Machine Versus Hand Sewing

A sewing machine is faster and produces a more even stitch, but a needle and thread work just as well. Machine stitching takes about 20 minutes for the three main seams. Hand sewing with a running stitch takes 45 minutes to an hour for the same seams, but you have more control and do not need to learn how to thread or tension a machine.

If you use a machine, set it to a straight stitch with a stitch length of 2.5 to 3 millimeters. Backstitch at the start and end of each seam to lock the thread. If you hand sew, use a running stitch — push the needle in and out of the fabric in one motion, making stitches about an eighth of an inch long. Smaller stitches are stronger but take longer.

Common Mistakes and How to Avoid Them

The most common error is cutting the fabric too small. Many people forget to add the seam allowance and end up with a cover that is too tight. Always add at least one inch to your measurements before you cut. The second mistake is sewing with the wrong sides together — if your seams end up on the outside, you have sewn inside-out. Check before you sew by looking at which side of the fabric is the print or pattern you want to see.

A third mistake is leaving the opening too small. Make sure the opening is at least as long as the shortest side of your pillow — if your pillow is 12 by 16 inches, the opening should be at least 12 inches. Trying to squeeze a pillow through a 6-inch opening is frustrating and can tear the fabric. Finally, do not skip trimming the corners. Untrimmed corners create thick, lumpy points that stick out and look unfinished.

Adding Zippers or Closures

If you want to remove and wash the cover, you can sew in a zipper instead of closing the fourth side by hand. A zipper opening is more durable than a hand-sewn seam and lets you take the cover off without undoing stitches. Measure your zipper to fit the opening — it should be about one inch shorter than the opening on each side.

Pin the zipper face-down along the opening, with the zipper teeth facing the inside of the cover. Sew along the edge of the zipper tape using a zipper foot on your machine, which lets you sew close to the teeth without hitting them. Fold the fabric edges over the zipper tape and topstitch (sew on the outside) to finish. If you do not have a zipper foot, a regular presser foot works but you will sew slightly farther from the teeth.

Frequently Asked Questions

What size should I cut the fabric if I do not have a pillow insert yet?

Measure the pillow you want to cover, or choose a standard size: 16 by 16 inches for a throw pillow, 12 by 20 inches for a lumbar pillow, or 20 by 20 inches for a larger cushion. Add one inch to both measurements, then cut two rectangles to that size. You can buy a pillow insert in the same size later.

Can I sew a pillow cover without a sewing machine?

Yes. Use a needle, thread, and a running stitch for all seams. It takes longer — about two hours instead of 30 minutes — but the result is the same. A running stitch is strong enough for a pillow cover as long as your stitches are small and even, about an eighth of an inch apart.

What thread should I use?

All-purpose polyester thread works for most fabrics and is inexpensive. Match the thread color to your fabric or use a neutral color like gray or tan. Avoid cheap thread that breaks easily — it makes sewing frustrating. One spool of thread is enough for several pillow covers.

How do I keep the fabric from slipping while I sew?

Pin the fabric every two inches along the seam line before you sew. Remove pins as you approach them with the needle or machine foot. If you are using a machine, a walking foot (an optional presser foot) feeds fabric evenly and prevents slipping on thick or slippery fabrics.

Can I make a pillow cover from old clothing or fabric scraps?

Yes, as long as you have two pieces large enough to cut your rectangles from. Old t-shirts, sheets, and jeans all work. Wash and dry the fabric first to remove any odors or dirt. Be aware that thin or worn fabric may tear during sewing — test a scrap first if you are unsure.