February 22, 2021

How to Sew an Envelope Pillow Cover

Envelope pillow covers are an easy sewing project to add color and comfort to any room.

Normally I would use envelope pillow covers to cover up existing pillows but mine are so nasty, I decided to buy pillow forms and make new pillow covers for them. I used cotton home decor fabric for this sewing project but any durable cotton fabric will work. I used 16″x16″ pillow forms for this sewing tutorial but this pattern will work for any size pillow form.

If you have leftover fabric, add easy fabric napkins and fabric placemats to your home decor sewing projects. You might also want to add a fun fabric rectangle basket for extra storage.

Here are the step-by-step instructions on how to make an envelope pillow cover.

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***You can find the ad-free, printable PDF version of this sewing tutorial available for purchase HERE. Includes 7-pages of step-by-step instructions with pictures. Print a copy to keep next to your sewing machine for easy reference.***

Envelope pillow cover supplies needed:

Durable washable cotton fabric – my favorite fabric shop
Pillow form (16″x16″ for this sewing project)
Cutting mat
Rotary cutter
Clear ruler
Sewing gauge
Sewing scissors
Matching thread
Straight pins
Sewing machine

Keep track of your sewing projects, like this one, with a sewing planner. This sewing planner is specifically designed for non-clothing sewing projects and helps you stay organized – fabric used, measurements, hardware used, notes, etc. Also included are pages such as sewing tips and fabric shops. Get your sewing planner H ERE.

Sewing project planner to help keep your sewing projects organized.

Cut the fabric

Using your cutting mat, clear ruler and rotary cutter, cut one piece of fabric measuring the same size as your pillow form. My pillow form is 16 inches by 16 inches therefore, I cut one piece of fabric 16 inches by 16 inches.

Cut two pieces of fabric measuring half of the length of your pillow form plus 5 inches by the width of your pillow form. In this case, half of the length is 8 inches plus 5 equals 13 inches. I cut two pieces of fabric 16 inches (W) by 13 inches (L).

Hem the fabric

Fold the bottom of one of the smaller fabric pieces 1/2 inch and press. If you are using fabric with a pattern, you’ll want to make sure the pattern is going in the proper direction.

Fold over again and press.

Straight stitch the hem.

Hem the top of the other smaller fabric piece using the same steps as above.

Finished hems on envelope pillow cover fabric pieces.

At this point, both smaller fabric pieces are hemmed – one bottom hem and one top hem, as shown in the above picture.

Sew it together

Place the fabric piece with the hem at the top on top of the larger fabric piece, right sides together, lining up the corners. Be sure to have the pattern going in the right direction.

Now place the fabric piece with the bottom hem on top of the other two fabric pieces, right side down, lining up the corners. Again, make sure the fabric is going in the right direction.