Sew the zipper between two fabric pieces before closing the pillow

A zipper in a pillow goes between the front and back panels, sewn in place before you join the rest of the seams. You position the zipper face-down on the right side of one fabric piece, stitch it down with a zipper foot, then flip the second fabric piece on top and sew all four sides. The zipper ends up sandwiched inside the seam, with the pull tab sticking out so you can open and close the pillow later. This method works for square, rectangular, or round pillows as long as the zipper is at least 2 inches shorter than the side where you place it.

The whole process takes about 30 to 45 minutes once you have your fabric cut and your zipper ready. You will need a sewing machine with a zipper foot attachment, thread that matches your fabric, pins, scissors, and a zipper that is 2 to 4 inches shorter than the side of your pillow. A 16-inch square pillow, for example, works well with a 12 to 14-inch zipper.

Key Takeaways

  • The zipper sits between the front and back fabric panels and gets sewn in during construction, not added afterward.
  • You need a zipper foot on your sewing machine—a regular presser foot will break the needle or skip stitches when it hits the zipper teeth.
  • Position the zipper face-down on the right side of your first fabric piece, with the pull tab pointing toward the center of the pillow.
  • Sew the zipper down with a 1/2-inch seam allowance, then place the second fabric piece on top and sew all four sides closed.
  • Leave a 1/2-inch gap at each end of the zipper so the seam allowance does not get caught when you open and close the pillow.

Cut your fabric and prepare the zipper

Cut two identical pieces of fabric to the finished size of your pillow plus 1/2 inch on all sides for seam allowance. A 16-inch finished pillow needs two pieces that are 17 inches by 17 inches. Lay one piece flat on your work surface with the right side (the pretty side) facing up.

Unzip your zipper completely and lay it face-down along one edge of the fabric, with the zipper tape running parallel to the edge. The pull tab should point toward the center of the fabric, not toward a corner. Leave at least 1/2 inch of space between the end of the zipper and the corner of the fabric on both sides—this prevents the seam allowance from getting pinched when you zip and unzip later. Pin the zipper tape to the fabric along its entire length, using 3 to 4 pins per side.

Attach the zipper foot and sew the first side

Swap your regular presser foot for the zipper foot. Most machines have a zipper foot that slides onto the presser bar and can be positioned on either side of the needle. Position it so the needle will run along the edge of the zipper tape, about 1/8 inch away from the teeth. This gap keeps the needle from hitting the metal and breaking.

Thread your machine with thread that matches your fabric. Lower the presser foot and begin sewing at one end of the zipper, using a straight stitch and a stitch length of 2.5 to 3.0 (medium length). Sew slowly and steadily along the entire length of the zipper tape. Stop about 1/2 inch before the end, backstitch to lock the thread, and cut the thread. Do not sew past the end of the zipper tape—you need that space to attach the second fabric piece without catching the tape in the seam.

Flip and sew the second fabric piece

Flip the fabric over so the zipper is now sandwiched between the two layers, with the zipper tape facing the back of the first fabric piece. Lay the second fabric piece on top, right side down, so the right sides of both fabric pieces face each other. The zipper is now between them. Pin the second fabric piece in place along the same edge where the zipper is attached.

Using the zipper foot again, sew along this edge with the same stitch length and the same 1/8-inch gap from the zipper teeth. This second line of stitching holds the zipper to the second fabric piece and creates a neat, symmetrical look on both sides of the pillow. Stop 1/2 inch before the end, backstitch, and cut the thread.

Close the remaining three sides

Swap back to your regular presser foot. The zipper is now fully attached and sandwiched between the two fabric pieces. Pin the remaining three sides of the pillow together, with right sides facing each other. Sew all three sides using a 1/2-inch seam allowance and a straight stitch at medium length (2.5 to 3.0).

At each corner, stop with the needle down, lift the presser foot, pivot the fabric 90 degrees, lower the presser foot, and continue sewing. This creates a sharp corner instead of a rounded one. When you reach the end of the third side, backstitch and cut the thread. Leave the fourth side (where the zipper is) open—the zipper itself is your opening.

Trim corners and turn the pillow right-side out

Trim the seam allowance at each corner to about 1/4 inch, cutting diagonally across the corner without cutting into the stitching. This removes bulk and helps the corners lie flat when you turn the pillow right-side out. Trim any loose threads.

Unzip the zipper about halfway. Reach into the opening and grab the fabric from inside, then pull the entire pillow through the zipper opening. The right sides of the fabric are now facing outward. Use a blunt tool like a chopstick or point turner to push the corners out from the inside so they are sharp and square. Press the pillow flat with an iron if you want crisp edges.

Insert the pillow form and close

Slide your pillow form or fiberfill stuffing through the zipper opening. If you are using a pillow form, make sure it fits snugly—a form that is slightly larger than the cover will make the pillow look fuller. If you are using loose fiberfill, fill the pillow until it feels plump but not rock-hard, then zip it closed.

Zip the zipper all the way closed. The seams should lie flat and the pillow should look finished on all sides. If any thread is visible along the zipper seams, trim it with small scissors.

Frequently Asked Questions

What size zipper do I need for my pillow?

The zipper should be 2 to 4 inches shorter than the side where you place it. A 16-inch square pillow works well with a 12 to 14-inch zipper. A 12-inch square pillow needs a 10 to 12-inch zipper. Measure the finished size of your pillow, subtract 2 to 4 inches, and buy a zipper that length.

Can I use a regular presser foot instead of a zipper foot?

No. A regular presser foot is too wide and will hit the zipper teeth, causing the needle to break or skip stitches. A zipper foot is narrow and can be positioned close to the teeth without hitting them. Most sewing machines come with a zipper foot, or you can buy one for $5 to $15 that fits your machine model.

What happens if I sew past the end of the zipper?

If you sew over the zipper tape at the end, the seam allowance gets caught in the zipper and the pillow will not open and close smoothly. Stop your stitching about 1/2 inch before the end of the zipper on both sides. This leaves room for the seam allowance to fold away from the zipper teeth.

Can I put the zipper on a different side of the pillow?

Yes. The zipper can go on any of the four sides, or even along a diagonal if you want a decorative look. Just make sure the zipper is at least 2 inches shorter than the side you choose, and follow the same steps: sew it to the first fabric piece, attach the second piece, then close the other three sides.

How do I fix a zipper that gets stuck after I sew it in?

A stuck zipper usually means thread or fabric is caught in the teeth. Gently wiggle the pull tab back and forth while pulling it slowly. If that does not work, rub a graphite pencil along the teeth to lubricate them, then try again. If the zipper is permanently stuck, you will need to remove the stitches with a seam ripper and replace the zipper.