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The easiest pillow cover is an envelope cover: hem two overlapping back panels, sew them to a front panel, and turn the cover right-side out. A hidden-zipper cover takes more alignment and hardware, but gives a more fitted, fully closed back. Both methods start with the finished measurements of your pillow insert.
Choose the closure before you cut
| Feature | Envelope closure | Hidden/invisible zipper |
|---|---|---|
| Extra supplies | Fabric, thread and ordinary sewing tools | An invisible zipper and zipper presser foot, in addition to fabric and thread |
| Construction | One front panel plus two hemmed, overlapping back panels | Two panels joined along a zipper, then sewn around the remaining three sides |
| Difficulty | Beginner-friendly; no zipper alignment | More precise; the zipper must be positioned and sewn close to its teeth |
| Opening | A concealed overlap at the back | A zipper running along the back seam |
| Changing or washing | Very easy to open and remove | Also removable, but the zipper adds a component to handle |
Use an envelope closure for a quick project, frequent seasonal changes or a first sewing attempt. Choose a zipper when you want the back to stay closed and the cover to look especially tailored.
Materials and measurements for either method
- Fabric, matching thread, scissors or a rotary cutter, a ruler or measuring tape, an iron and pins or clips
- A sewing machine, or a needle and thread if you are hand-sewing
- An invisible zipper and zipper foot for the zipper version
Measure the insert, not the old cover. Record its finished width and height, then add the seam allowance required by your pattern. If the insert is square, both measurements are the same. Pressing each seam as you work produces a cleaner cover, and clipping bulky corners before turning helps them become sharp.
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1. Plan the panels
Cut one front panel to the finished insert dimensions plus your seam allowance. Cut two back panels to the same height. Their combined widths must cover the back and overlap at the opening. Sailrite’s envelope method uses a 6-inch overlap; Fairfield World’s example adds 2.5 inches to half the pillow width for each back piece. Those are pattern examples, not universal rules, so use the overlap your insert and fabric require. Sailrite notes that an envelope cover can be made for any pillow size.
#1 Best Overall
- Package: This embroidery kit will include 2 x pillowcase covers with drawings and zippers (unfinished and do not contain pillow stuffing), 2 x instructions, 6 x needles, and embroidery threads. Note: The frame is not included.
- Size Detail: Pillow Cover: 42*42cm, it can match 45*45cm pillow core.
- Premium Quality: Cotton pillowcover. The smooth, three-dimensional threads have a bright, brilliant color with a silky texture, ensuring no knots and a softer, continuous feel after multi-process processing for a high-quality finish.
- Easy to Follow: The product takes DIY diamond embroidery to a unique level. You can enjoy its beauty after finishing the pillowcases in less than 2 days with included instructions. It encourages your family to join together and experience the effort of cross-stitching.
- Gift For Anyone: Suitable for both beginners and experienced needlework lovers and embroiders. It features an easy lavender and chamomile stitch pattern for hand-craft enthusiasts. Still great after washing.
2. Hem the opening edges
On each back panel, fold the long edge that will form the opening to the wrong side, press it, fold again to hide the raw edge, and stitch the hem. Keep the two finished edges parallel; they will meet at the center back and overlap.
3. Layer the cover
Place the front panel right-side up. Lay one back panel on top, right-side down, aligning its outer edges with the front. Place the second back panel over it, also right-side down, so the hemmed edges overlap at the center. Pin or clip around the entire perimeter and check that the overlap has not shifted.
Rank #2
- Kit Includes: Two standard 20” x 30” pillowcases (65% Poly/35% Cotton) and feature designs that are stamped on the fabric. Design is printed with easy to follow blue ink that will easily wash out.
- FLOSS NOT INCLUDED. Package includes a suggested floss shopping list or you can use colors to match your personal home decor.
- Finished Size: 20" x 30" each
- Made in the USA
4. Sew, trim and turn
- Sew all four outer sides using the seam allowance chosen for your pattern.
- Trim or grade the seam allowances and clip the corners without cutting through the stitching.
- Turn the cover right-side out through the overlapping back opening.
- Push the corners out gently, press the cover flat and insert the pillow form.
The overlap stays concealed behind the pillow while remaining accessible whenever you need to remove the cover.
How to make a hidden-zipper pillow cover
1. Cut two matching squares
For a 20-inch pillow insert, AllPeopleQuilt’s 2025 worked example cuts two 21-inch fabric squares. That size accounts for a 1/2-inch seam allowance on each side. For a different insert, recalculate from the finished insert dimensions and your chosen seam allowance rather than copying the 21-inch measurement.
Rank #3
- Copyright 1988
2. Prepare the zipper edge
- Press open the fold in the zipper tape so the tape lies flat.
- Place the zipper face down along one fabric edge, aligning the zipper tape with the fabric’s right side.
- Use an invisible-zipper presser foot to stitch close to the raised zipper teeth. The foot keeps the needle near the teeth while allowing them to feed through the groove.
3. Attach the second panel
Align the second square with the opposite zipper tape, right sides together as directed by your pattern, and sew the remaining zipper side. Close the zipper temporarily and check that the top edges and corners align before continuing.
4. Sew the remaining sides
- Open the zipper partway so the pull will not block the seam.
- Align the three unsewn edges and stitch them with a 1/2-inch seam allowance in the AllPeopleQuilt example.
- Clip the corners, trim excess zipper tape and turn the cover right-side out.
- Press carefully and insert the 20-inch pillow form.
Closing the zipper before sewing the other sides helps you verify alignment; reopening it before the final seams gives you an opening for turning the cover.
Rank #4
- 【High Quality】Embroidery Pillow is made of high-quality fabric, the texture of the fabric is especially suitable for embroidered.
- 【Embroidery Decoration】After finishing the embroidery, the embroidery pillow can be puted in the living room, bedroom, study room, , commercial space, car or other places.
- 【Easy to Learn】Simple DIY instructions and takes about 1 to 2 days to complete. They take less time and effort than cross stitch. This embroidery cushion cover kit is fit for adults, beginners, handicraft lovers, etc.
- 【Package Include】This embroidery kit will include pillowcase, , instruction. ( and frame not included.) Size Chart: Approx.44x44cm/17.32x17.32 inch.
- 【Perfect Gift】A perfect and meaningful gift for your family and friends, a decoration, it can be also used as wedding gift, birthday gift, Valentine gift.
How much fabric do you need?
There is no single fabric amount for every pillow cover. Start with the insert’s finished width and height, add seam allowance to every sewn edge, then account for the closure:
- Envelope: one front panel plus two back panels. The back panels must overlap at the center; the overlap may be 6 inches in Sailrite’s pattern or 2.5 inches added to half the pillow width in Fairfield World’s example.
- Hidden zipper: two panels. AllPeopleQuilt’s 20-inch example uses two 21-inch squares, with a 1/2-inch seam allowance around the sewn edges.
Before cutting, compare the panel dimensions with your fabric’s usable width. If a panel will not fit across the fabric, plan a seam, rotate the layout or buy enough yardage for a different cutting arrangement.
Best Value
- Package: This embroidery kit will include 2 x pillowcase covers with drawings and zippers (unfinished and do not contain pillow stuffing), 2 x instructions, 6 x needles, and embroidery threads. Note: The frame is not included.
- Size Detail: Pillow Cover: 42*42cm, it can match 45*45cm pillow core.
- Premium Quality: Cotton pillowcover. The smooth, three-dimensional threads have a bright, brilliant color with a silky texture, ensuring no knots and a softer, continuous feel after multi-process processing for a high-quality finish.
- Easy to Follow: The product takes DIY diamond embroidery to a unique level. You can enjoy its beauty after finishing the pillowcases in less than 2 days with included instructions. It encourages your family to join together and experience the effort of cross-stitching.
- Gift For Anyone: Suitable for both beginners and experienced needlework lovers and embroiders. It features an easy lavender and chamomile stitch pattern for hand-craft enthusiasts. Still great after washing.
Common problems and fixes
The envelope opening gaps
The back panels may not overlap enough, or the insert may be fuller than expected. Remove the cover and measure the overlap flat; increase the back-panel width on the next version rather than narrowing the front panel.
The zipper cover puckers
Uneven zipper stitching, a zipper sewn too far from the teeth or misaligned panel edges can create ripples. Baste or clip the second side, close the zipper to check the alignment, and sew slowly with the zipper foot guiding the teeth.
The corners look blunt
Untrimmed seam bulk prevents the fabric from turning fully. Clip diagonally toward—but not through—the stitching, then turn with a blunt point such as a turning tool and press.
Which method is easier?
The envelope method is easier because it replaces zipper installation with two straight hems and an overlap. It needs only basic fabric and sewing tools and is forgiving when you are learning. The hidden zipper method is the better choice when a closed, fitted back matters more than speed: it adds hardware, a specialized foot and alignment checks, but avoids a visible overlap.
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