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How to Make an Envelope Cushion Cover: Easy, No Zip, One Half Metre

by In Stitches Nairobi on Oct 15, 2026
Quilting cotton prints for cushion covers

A new set of cushion covers changes a room for the price of a few half metres of fabric. The envelope cover is the easiest one to sew: no zip, no buttons, just four straight seams and two hems.

The back is made from two overlapping pieces, so the cushion slips in through the gap. It is the perfect first sewing machine project, and a lovely one to make in sets.

What you need

Quilting cotton: one half metre makes a 40 or 45 cm cover. See the table below for other sizes.

A cushion insert.

Matching polyester thread and a universal size 80 machine needle.

Pins or Clover Wonder Clips, a tape measure and sharp scissors, or a rotary cutter.

Cutting sizes

Cut the front the same size as your cushion insert. With a 1 cm seam the finished cover is 2 cm smaller than the insert, which gives a full, plump cushion rather than a baggy one.

Cushion insert Front: cut 1 Back: cut 2 Fabric to buy
40 x 40 cm 40 x 40 cm 40 x 27 cm 0.5 m
45 x 45 cm 45 x 45 cm 45 x 30 cm 0.5 m
50 x 50 cm 50 x 50 cm 50 x 33 cm 1 m
60 x 60 cm 60 x 60 cm 60 x 40 cm 1.5 m

How a 45 cm cover fits in a half metre

Our fabric is 112 cm wide. Cut a 45 cm strip across the full width, then cut it into the front (45 cm) and two backs (30 cm each). That uses 105 cm of the width, with a little to spare for straightening the edges.

Step by step

1. Wash and press

Pre-wash the fabric if you will wash the cover, then press it flat. Cut your three pieces, keeping any pattern the right way up.

2. Hem the back pieces

On one long edge of each back piece, fold 1 cm to the wrong side and press. Fold another 1.5 cm and press again. Stitch close to the inner fold.

3. Layer the pieces

Lay the front right side up. Place the two backs on top, right side down, with the hemmed edges overlapping in the middle and the raw edges lined up with the front.

4. Pin or clip

Pin or clip all the way round, with extra pins where the backs overlap so the layers cannot shift.

5. Sew all round

Stitch 1 cm from the edge on all four sides. Sew back and forth over the overlap a couple of times, because that is where the cover takes the strain.

6. Trim and finish

Snip the corners off diagonally, close to the stitching but not through it. Zigzag the raw edges so they do not fray in the wash.

7. Turn and press

Turn the cover right side out through the opening. Ease the corners out with a blunt tool such as a knitting needle, never the point of the scissors, then press.

8. Fill it

Fold the insert in half, push it in through the envelope, and plump it out into the corners.

Make it your own

Use a different fabric for the back. A print on the front with a Kona solid on the back looks smart, and means two half metres make two covers that match.

Turn the cushion over: a reversible pair gives you two looks for one sofa.

Piece the front from fat quarters for a patchwork cushion, a gentle first step towards quilting. Our guide to choosing fabrics that go together will help.

Ready for more? Robert Kaufman's free Nova Star throw pillow pattern is a good next step.

Choose your fabric

Over 150 quilting cotton prints and a full range of solids, at our shop at Muthaiga Mini Market or delivered across Kenya.

Shop quilting cotton

Or message us on 0798 316 860

Prices correct at the time of writing.

Tags: Beginners, Home Decor, How To, Quilting, Quilting Cotton, Sewing
Previous
What Can You Make with Quilting Cotton? (And When to Choose Something Else)
Next
Christmas Sewing Projects: Bunting, Gift Bags, Table Runners and More

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