It’s no secret I love to make pillows. I have dozens I’ve made that are stored in my guest-room closet just waiting for the perfect home. Maybe I’ll list them on Etsy or eBay? Once upon a time I tried selling pillows at a craft sale. Wrong sale, wrong type of product or both. I’m sure I’ll find them homes eventually. {hope, hope} I picked up a great drapery workroom trick in the process of cranking out over one hundred pillows. Making my own pillow forms. No more running to JoAnn’s for pillow inserts that never feel exactly as nice and full as I’d like them to feel and they can be less expensive when you make them too. It’s an absolute necessity if you choose to make oddly shaped (not square, rectangular or round) pillow inserts as you’ll see by my example below. If you have a serger, you can whip up a custom-sized form in a few minutes. If you don’t have a serger, you can crank one out in just a few minutes more. It’s that easy.
First, determine the size of your finished pillow insert. A drapery workroom secret is to use a form a couple of inches larger than the size of the finished pillow cover. This creates a truly luxurious pillow worthy of your beautiful home! A lot of people ascribe to the notion that the pillow form should be the same size as the cover but, trust me, you’ll get a more professional look when you up-size your form. There is one caveat, however. If your cover has a button or flap closure, a larger form may cause the opening to gap some. You know, like when your blouse buttons just a little to tightly in the front {or so I hear
} so in this case, stick more closely to the size of your pillow cover.
You can use any number of fabrics to create your form. I’ve used scrap drapery lining, muslin, napped sateen* drapery lining (place the napped side outward to beef up a thinner pillow fabric) or even plain white sheeting. I try to stick with 100% cotton, unprinted fabric but in certain cases I suppose you could use just about any scrap fabric if your cover isn’t transparent. Once you’ve decided on the size of form you’d like to make, cut two pieces of the fabric you chose for your cover 1″ larger in width and height than the completed form’s size.
When constructing your own pillow inserts, there aren’t a lot of available options with regard to the material used to fill them. Actual down and/or feathers would make a horrible mess! As a rule I use a polyester cluster filler with the look and feel of down. JoAnn’s carries a product similar to what I use which you can see here. This type of filling can make the pillow karate choppable (if you are so inclined). Don’t necessarily go for the cheapest you can find (unless you have a coupon).
If you’ll be serging the form, simply serge around all four sides with a 1/2″ seam, allowing the machine to trim to 1/4″. Be sure to leave an opening away from the corners large enough to get your hand into for filling.
Fill the form with the poly cluster stuffing so that it’s nice and full and then serge closed.That’s it! It’s ready to go! (And no, I don’t sew in the dark. I have virtually no natural light in my sewing studio.)
If you’re sewing on a straight-stitch machine, sew your pieces (right sides together) using a 1/2″ seam leaving an opening away from the corners large enough to get your hand into so that you can stuff all corners. Turn right side out, clip corners and stuff. I stitch the opening closed with my machine but you can hand stitch closed as well.
Don’t be stingy with the filling or your pillow will look flat. A flat pillow is not what we’re going for. We want a nice, plump pillow.
A serged or straight-stitched insert won’t make any difference really once your pillow has been stuffed. Serging is just quicker.
And if you’re making a boxed style pillow, be sure to box the insert as well. The process is the same as constructing a boxed pillow, again make it a little larger than the pillow cover. 
Easy, right? Try it and let me know what you think!
*Napped sateen drapery lining may be hard to find. It’s used by workrooms when lining plus interlining isn’t desired, but a more substantial lining is. The sateen side is on the left of the photo below. The napped side is on the right.











































































































































































