Two Ways to Make Pillow Covers: Envelope or Hidden Zipper

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The easiest removable pillow cover is an envelope cover: hem two overlapping back panels, layer them behind a front panel, and sew around the perimeter. A hidden-zipper cover takes more alignment and hardware but gives the back a more fitted, continuous finish. Both methods start with the pillow insert’s finished width and height.

Choose the closure that fits your project

Supplies and measurements

For either method, gather fabric, matching thread, scissors or a rotary cutter, a ruler or tape measure, an iron, pins or clips and a sewing machine. Hand sewing is also possible, although it takes longer. Measure the insert itself rather than relying on its label, recording its finished width and height.

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• Use a seam allowance consistently on every sewn edge.
• Prewash and press washable fabric if shrinkage could affect the finished fit.
• Cut accurately; small errors are especially visible on a fitted cover.

Method 1: Make an envelope pillow cover

This closure needs no zipper. One front piece is backed by two pieces whose finished inner edges overlap at the opening. Sailrite notes that an envelope-style cover can be made for any pillow size; its example creates a 6-inch overlap. Fairfield World’s example adds 2.5 inches to half the pillow width for each back piece, while other patterns use their own overlap and seam-allowance choices. Follow one formula consistently rather than combining figures from different patterns.

Cut the panels

1. Measure the insert’s finished width and height.
2. Cut one front panel to the desired finished dimensions plus your seam allowance on all sides.
3. Cut two back panels at the same finished height plus seam allowances. Set each back width to the portion of the insert width it must cover, plus the chosen overlap and seam allowances. For the Fairfield World example, each back width is half the pillow width plus 2.5 inches before accounting for the pattern’s seam treatment.

Hem the opening edges

1. On each back panel, fold the long inner edge to the wrong side by the planned hem allowance and press.
2. Fold again to enclose the raw edge, press, and stitch the hem.

Assemble and sew

1. Lay the front panel right side up.
2. Place one back panel right side down over it, aligning the outer edges. Place the second back panel right side down from the opposite edge so the two hemmed edges overlap at the center.
3. Pin or clip all around the perimeter, checking that the overlap remains in the planned position.
4. Sew around all four sides with the selected seam allowance. Backstitch at the start and finish.
5. Trim bulky corners without cutting the stitching, then turn the cover right side out.
6. Push the corners out, press the cover, and insert the pillow form.

The overlap stays concealed when the cover is on the pillow and can be opened quickly for laundering or seasonal changes.

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Method 2: Make a hidden-zipper pillow cover

A zipper cover joins two equal panels and hides the closure along one edge. In AllPeopleQuilt’s published 2025 example, a 20-inch pillow insert uses two 21-inch fabric squares; the extra inch provides a 1/2-inch seam allowance on each side.

Prepare the zipper edge

1. Press open the fold in the invisible-zipper tape so the teeth can sit close to the seam line.
2. Place the zipper face down on the first fabric edge and sew it with an invisible-zipper foot or zipper foot. The foot keeps the needle close to the raised teeth.
3. Align the second fabric panel with the opposite zipper tape, checking that the corners and pattern (if any) will match, and sew the second side.
4. Close the zipper and inspect the alignment before sewing the remaining seams.

Finish the cover

1. With right sides together, sew the three edges that do not contain the zipper, using a 1/2-inch seam allowance in the AllPeopleQuilt example.
2. Clip the corners and trim excess zipper tape, keeping the zipper slider and stitching intact.
3. Turn the cover right side out, press it, and insert the 20-inch pillow form.

How much fabric do you need?

Fabric use depends on the insert dimensions, seam allowance, overlap, fabric width and pattern matching. Calculate the cut pieces first, then check whether they fit across the fabric’s usable width.

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• Envelope: one front rectangle and two back rectangles. The back rectangles must cover the opening and overlap by the amount selected in your pattern; Sailrite’s cited example uses 6 inches, while Fairfield World’s example adds 2.5 inches to half the pillow width for each back piece.
• Hidden zipper: two rectangles or squares sized to the finished insert plus seam allowances. The cited 20-inch-square example cuts two 21-inch squares, using 1/2 inch per sewn edge.

If the required pieces do not fit across the fabric, rotate the layout only if the fabric’s nap, print direction and stretch allow it, or plan a deliberate seam.

Fit checks before the final seam

• Confirm the insert’s measured dimensions and the finished cover dimensions before cutting.
• For an envelope, verify that both back panels overlap fully at the center without leaving a gap.
• For a zipper, close it partway and match the top and side edges before sewing the remaining seams.
• Test the cover with the insert after pressing; a slightly firm fit usually looks neater than a loose, sagging cover, but do not force the form into a cover that is materially smaller than planned.

Common problems and fixes

The envelope opening shows a gap

The back panels are too narrow or were positioned without the planned overlap. Recheck the cut widths and center the overlap before stitching the perimeter.

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The zipper cover has uneven corners

Unequal seam allowances or zipper ends that were not aligned can shift the panels. Close the zipper, square the edges, mark the seam line, and sew the remaining sides from the zipper edge outward.

The corners look bulky

Trim the seam allowance diagonally near each corner, stopping short of the stitching, then turn and press carefully.

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