Measure Your Pillow and Cut Your Fabric
Start by measuring the pillow insert you plan to use. Measure the length and width, then add one inch to each dimension for seam allowance. For example, if your pillow is 16 inches square, cut two fabric pieces that are 17 inches square.
Cut your fabric pieces using a rotary cutter and ruler, or mark lines with chalk and cut with scissors. Make sure both pieces are exactly the same size. Lay them flat on a clean surface with the right sides (the pretty sides) facing each other.
Key Takeaways
- Measure your pillow insert and add one inch to both dimensions before cutting fabric, so your finished cover fits snugly.
- A zipper should be slightly shorter than the width or length of your pillow — a 14-inch zipper works for a 16-inch pillow.
- Sew the zipper to one edge before assembling the cover, using a zipper foot attachment on your machine.
- Sew three remaining sides closed with a straight stitch, then turn the cover right-side out through the zipper opening.
- Press seams flat with an iron before inserting the pillow, so edges look crisp and professional.
Choose and Prepare Your Zipper
Buy a zipper that is 1 to 2 inches shorter than the side where you want it. For a 16-inch pillow, a 14-inch zipper works well. Coil zippers (also called continuous zippers) are cheaper and come in longer lengths that you can cut to size, but metal or plastic separating zippers are easier for beginners because they stay put.
Before you attach the zipper, test it by opening and closing it several times. If it sticks or catches, run a pencil along the teeth on both sides — the graphite lubricates the slider. Trim any loose threads from the zipper tape with scissors.
Attach the Zipper to One Fabric Piece
Lay one fabric piece right-side up on your work surface. Place the zipper face-down along one edge, with the zipper teeth pointing toward the fabric and the zipper tape sitting on top of the seam allowance (the 1-inch border you added). The zipper should be centered on that edge, with equal space on both sides.
Install a zipper foot on your sewing machine — this is a narrow presser foot that lets you stitch close to the zipper teeth without hitting them. Set your machine to a straight stitch and a medium stitch length (around 2.5). Sew the zipper to the fabric, stitching about one-quarter inch away from the zipper teeth. Sew from one end of the zipper to the other, then backstitch at the end to lock the thread.
Flip the fabric over so the zipper is now underneath. Fold the fabric edge down so the zipper is hidden between the two layers of fabric and seam allowance. Press this fold flat with an iron on medium heat. This step keeps the zipper from getting caught when you sew the other sides.
Sew the Zipper to the Second Fabric Piece
Lay the second fabric piece right-side up. Place it on top of the first piece so the right sides are facing each other and the edges line up. The zipper is now sandwiched between the two pieces. Using the zipper foot again, sew along the same edge, stitching about one-quarter inch from the zipper teeth. This secures the zipper to both pieces at once.
Open the zipper halfway — this is important. If you sew the cover completely closed with the zipper shut, you will not be able to turn it right-side out later. Unzip it now so you have an opening to work with.
Sew the Three Remaining Sides
Switch back to your regular presser foot (not the zipper foot). With the fabric still right-sides together, sew the three remaining sides using a straight stitch. Start at one corner and sew about one-half inch from the edge — this is your standard seam allowance. Sew all the way around, stopping one-half inch before you reach the starting point, then backstitch to lock the thread.
At each corner, stop with the needle down, lift the presser foot, rotate the fabric 90 degrees, lower the presser foot, and continue sewing. This creates sharp corners instead of rounded ones. Trim the corners diagonally about one-quarter inch from the stitching — this reduces bulk when you turn the cover right-side out.
Turn the Cover Right-Side Out and Press
Reach through the zipper opening and grab the fabric from inside. Pull gently and steadily until the entire cover is turned right-side out. Use a blunt tool like a chopstick or the eraser end of a pencil to push the corners out from the inside so they are sharp and square.
Lay the cover flat on your ironing board and press all four seams with a medium-heat iron. Press the zipper seam from the outside, then flip and press from the inside. This flattens the seams and makes the cover look finished and professional. If any threads are sticking out, trim them with small scissors.
Insert the Pillow and Close the Zipper
Open the zipper all the way. Slide your pillow insert into the cover through the opening. Make sure the corners of the pillow go into the corners of the cover, and the pillow sits evenly inside. Close the zipper slowly and smoothly, checking that the fabric is not caught in the slider as you go.
If the zipper feels stiff or stuck, stop and check for trapped fabric. Gently work the slider back and forth until it moves freely, then continue closing. Once the zipper is fully closed, your pillow cover is complete.
Frequently Asked Questions
Can I use a regular presser foot instead of a zipper foot?
You can, but it is harder to sew close to the zipper teeth without hitting them and breaking your needle. A zipper foot costs five to ten dollars and makes the job much easier. Most machines come with one, or you can buy a universal zipper foot that fits any machine.
What do I do if my zipper is too long for my pillow?
If you are using a coil zipper, you can shorten it by sewing a few stitches across the coil about one-quarter inch beyond where you want it to end, then trimming the excess tape. For metal or plastic zippers, buy the correct length instead — cutting them usually damages the slider.
Why does my zipper keep getting stuck?
Stuck zippers are usually caused by fabric caught in the slider or dried-out teeth. Stop and check for trapped threads or fabric. If the teeth are dry, rub a pencil, graphite stick, or bar of soap along both sides of the zipper. Never force a stuck zipper — you will break the slider.
Do I have to open the zipper before sewing the cover closed?
Yes. If you sew the cover completely closed with the zipper shut, you will not have an opening to turn it right-side out. Open it at least halfway before you sew the remaining three sides.
How do I keep the zipper from puckering along the seam?
Puckering happens when the zipper tape shifts while you sew. Pin the zipper to the fabric before sewing, placing pins perpendicular to the zipper about every two inches. Remove pins as you sew. Sew slowly and keep tension even on both sides of the presser foot.