Tutorial: How to Make a Pillow Cover with Invisible Zipper

Cindy CullingsSeptember 1, 2020

If you are looking for a gift idea for nearly any occasion, a custom embroidered throw pillow is always a lovely choice. Linen pillows with names and dates are my preferred gift for newlyweds and anniversary gifts. Washable cotton pillows with state outlines and reminders of home make wonderful gifts for graduating seniors to take to their college dorm rooms. I am going to show you how to make these pillows from start to finish, including how to put in the invisible zipper!

All machine embroidery fonts and elements shown in this tutorial are available to purchase on this website

First, let’s talk about supplies. I prefer to use a heavy linen material for most of my pillows. I find this fabric durable, holds stitches well, and is generally a nice neutral color that matches most decor. The downside is it is not as easy to launder, so I typically reserve this fabric for wedding gifts. For other zippered pillow covers, such as those for college students or children, I will use a pre-washed cotton fabric.

Pillow form- any size
Fabric- enough to cut two pieces of equal size for the front and back of the pillow form
Invisible zipper- color match as closely as you can to your fabric

Cut two fabric pieces the dimensions of your pillow form + ½” . My pillow form is 12” x 16”, so I cut two pieces- each 12 ½” x 16 ½”.

Use your embroidery machine to sew a beautiful design on one of the pillow pieces.

(Optional) If you have a serger, serge around the edges of both pillow pieces to minimize raveling.

Place right sides together and pin the front piece to the back piece, then pin the edge where the zipper will go.

Lay your invisible zipper down to mark where you want the beginning and end to be.

If you have a zipper longer than the length of the pillow, plan to sew about 2” in from each end on the next step.
If you have a shorter zipper length, you’ll want to make sure you sew a longer length from each end.

Using a regular stitch length, and a 5/8” seam allowance, sew from the end of the fabric to where you marked, and be sure to backstitch. Do the same stitching at the other end of the pillow edge.

Lay the stitched pillow pieces face down with your new seam facing up. Lay your zipper face down on the seam, making sure the zipper pull is above where the pillow opening will be.

Unzip and lay the zipper over the opening.

Pin one side of the zipper to the seam allowance. Do not pin through the front layer of the pillow cover.

To be sure you have the pins through only one layer, fold the top layer back as shown in the photo.

Now pin the other side of the zipper to the opposite side of the seam allowance.

You may find it easier to pin if you fold back the bottom layer as shown in the photo.

Before you sew, make sure the top zipper pieces line up as perfectly as possible so your finished zippered area won’t have a gap.

Using your zipper foot, sew each zipper length, backstitching at each end. With your left hand, roll the zipper teeth flat and stitch as close as you can to the zipper teeth.