What you need to sew a towel

A towel is one of the easiest sewing projects because it is mostly straight seams and does not require fitted pieces or closures. You can make a basic towel from two pieces of absorbent fabric (usually terry cloth or cotton) sewn together on three sides, then turned right-side out and closed by hand. You can also repair a torn towel by patching it or re-hemming a frayed edge.

To start, gather a sewing machine (or needle and thread if you are hand-sewing), thread that matches your fabric, scissors or a rotary cutter, a ruler or measuring tape, pins, and two pieces of fabric cut to the same size. Terry cloth is the most common choice because it absorbs water, but you can use any cotton fabric. A standard bath towel is roughly 27 inches by 52 inches, but you can make yours any size you want.

If you are repairing a towel instead of making one from scratch, you will also need a patch of matching or complementary fabric and a seam ripper if you need to remove old stitches.

Key Takeaways

  • A basic sewn towel requires two pieces of fabric the same size, pinned together and sewn on three sides with a quarter-inch seam allowance.
  • After sewing three sides, turn the towel right-side out through the opening, then close the fourth side by hand using a ladder stitch or whip stitch.
  • To repair a torn towel, you can sew a patch over the hole from the back side or use fusible webbing to bond a patch without stitching.
  • A frayed edge can be fixed by trimming the loose threads and sewing a new hem, or by binding the edge with bias tape.

Sewing two pieces of fabric into a towel

Start by cutting two pieces of fabric to the same dimensions. Lay them on top of each other with the right sides facing each other — this means the pretty sides are touching and the back sides face outward. Pin around all four edges to hold them in place while you sew.

Using a sewing machine set to a straight stitch, sew along three of the four sides with a quarter-inch seam allowance (the distance from the edge of the fabric to your stitching line). Leave one short end completely unsewn — this is your opening for turning the towel right-side out. Backstitch at the beginning and end of each seam to lock the thread.

Trim the corners diagonally, cutting away the excess fabric at a 45-degree angle about a quarter-inch from the corner seam. This prevents the corners from bunching when you turn the towel right-side out. Clip the seams along the curved or angled edges if your towel has any, cutting small notches perpendicular to the seam without cutting through the stitching itself.

Turning and closing the towel

Reach through the unsewn opening and grab the fabric from the inside. Pull gently and steadily until the entire towel is turned right-side out. The seams should now be hidden on the inside, and the pretty sides should face outward. Use a blunt tool like a chopstick or the eraser end of a pencil to push the corners out fully from the inside.

Press the towel flat with an iron, paying special attention to the opening. Fold the raw edges of the opening inward by about a quarter-inch on both sides and press them flat. Pin the opening closed.

Close the opening by hand using a ladder stitch (also called a whip stitch). Thread a needle and knot the end. Bring the needle up through one folded edge, then slide it horizontally inside the fold for about a quarter-inch. Come back out and cross over to the opposite folded edge, then slide the needle inside that fold for another quarter-inch. Continue this back-and-forth motion, keeping your stitches small and tight. When you reach the end, knot the thread on the inside and trim it.

Patching a hole in an existing towel

If your towel has a small tear or hole, you can patch it without replacing the entire towel. Cut a patch from matching or complementary fabric that is at least an inch larger than the hole on all sides — a 4-by-4-inch patch works well for most small holes. Round the corners of the patch slightly so they do not fray as easily.

Turn the towel inside out and pin the patch over the hole, covering it completely. Sew around the edges of the patch using a straight stitch, staying about a quarter-inch from the edge. You can also use a zigzag stitch around the perimeter to prevent fraying. Trim any loose threads and press the patch flat.

Alternatively, use fusible webbing (a heat-activated adhesive sheet sold in fabric stores) to bond the patch without sewing. Cut the webbing to the same size as your patch, place it between the patch and the towel, and press with a hot iron according to the webbing package instructions. This method is faster but less durable than sewing.

Fixing a frayed or worn edge

Towel edges fray naturally over time, especially after repeated washing. If the fraying is minor, straightforward trim the loose threads with scissors and sew a new hem. Fold the edge inward by about a quarter-inch, press it flat, then fold it again and press. Sew along the fold using a straight stitch, staying close to the inner fold.

For a more finished look, use bias tape — a pre-made strip of fabric folded and pressed into a binding. Open one fold of the bias tape and pin it to the edge of the towel, right sides together, so the crease of the tape aligns with the edge of the towel. Sew along the crease using a quarter-inch seam allowance. Fold the bias tape to the back side of the towel and pin it in place, then sew it down by hand or machine, keeping your stitches close to the inner fold of the tape.

Hand-sewing a towel if you do not have a machine

You can sew a towel entirely by hand, though it takes longer. Use a running stitch — push the needle in and out of the fabric in a straight line, making stitches about a quarter-inch long. Keep the stitches as even as possible and pull the thread snug after every few stitches so the seam stays tight.

For the opening, use the same ladder stitch described above. Hand-sewing is actually easier for the closing seam because you can see exactly where your needle is going and adjust as you work.

Choosing fabric and thread for durability

Terry cloth is the standard choice for towels because the looped pile absorbs water and feels soft. It comes in different weights — heavier terry is more absorbent and durable, while lighter terry is softer but wears out faster. You can also use regular cotton fabric, linen, or a cotton-linen blend, though these will not absorb as much water.

Match your thread to your fabric color as closely as possible. Use all-purpose polyester thread for most projects — it is strong and works well on both natural and synthetic fabrics. If you are sewing terry cloth, make sure your needle is a size 80/12 or 90/14 universal needle, which handles the thick, looped fabric without breaking.

Frequently Asked Questions

Can I sew a towel with a serger instead of a regular sewing machine?

Yes. A serger (also called an overlock machine) creates a finished edge that prevents fraying, which is ideal for towels. Use a four-thread serger stitch on the seams and follow the same basic steps — sew three sides, turn right-side out, and close the fourth side by hand or with a serger if your machine allows.

What is the best stitch length for sewing towel fabric?

Use a stitch length of 2.5 to 3 millimeters on a regular sewing machine. This is slightly longer than a standard stitch and prevents the needle from piercing the towel loops too many times, which can weaken the fabric. Test on a scrap of your fabric first.

Do I need to wash a new towel before sewing it?

It is a good idea to wash and dry your fabric before cutting and sewing, especially terry cloth, because it shrinks slightly in the wash. Pre-washing prevents your finished towel from shrinking unevenly after you use it. Use warm water and a gentle cycle.

How do I fix a towel that is unraveling at the seams?

Remove the old stitches using a seam ripper, then re-sew the seam using a straight stitch with matching thread. If the fabric itself is damaged, trim away the damaged section and sew a new seam slightly inward from the original line. You can also reinforce the seam by sewing over it a second time with a zigzag stitch.

Can I add decorative elements like embroidery or appliqué to a towel?

Yes. Embroider or appliqué before you sew the two pieces together — it is much easier to work on a flat, single layer. Sew your design onto one piece of fabric, then proceed with the basic towel-sewing steps. Keep embroidery away from the seam allowance so your stitches do not get caught when you sew the pieces together.