How to sew a zip into a cushion cover
A zip makes a cushion cover removable and, depending on the material, easier to clean or refill. For a neat result, consider the zip type, position, seam allowance and fabric thickness.
Choose the zip
A flexible plastic coil zip works well for many cushion covers. Make the opening large enough to insert the inner cushion or foam without putting excessive strain on the seams. For damp environments, both the zip and fabric should be suitable for the application.
Preparation
Cut the front and back panels with sufficient seam allowance. Use suitable thread, a zipper foot and clips or pins appropriate to the material. Pins can leave permanent holes in faux leather.
Zip in the bottom seam
Place the fabric panels right sides together and mark the zip position. Sew the seam sections beyond the opening permanently. The section over the zip can be closed with an easily removable basting stitch. Open or press the seam allowances according to the fabric’s care and heat requirements.
Centre the closed zip beneath the seam and secure it. Using a zipper foot, stitch evenly along both sides and secure the ends. Carefully remove the basting stitches above the teeth afterwards.
Close the cover
Partly open the zip before sewing the remaining sides so the cover can be turned right side out afterwards. Trim corners only enough to reduce bulk without weakening the seam.
Common problems
Waviness is often caused by stretching the fabric or zip while sewing. Let the machine feed the layers and stabilise stretchy fabrics where necessary. Also make sure the stitching does not catch the teeth and that the opening is large enough for the filling.
