How to make a badge cover

1. Materials & tools

Materials (one cover, 57 mm badge)

• Main fabric (light cotton) — about 12 × 30 cm
• Clear vinyl (0.3 mm) — about 10 × 10 cm
• Size 9 needle and fine thread
• Clips instead of pins
• A Teflon foot, if you have one

Tools

• Sewing machine (or needle and thread)
• Fabric marker or pencil
• Ruler and scissors
• Iron
• Pins or clips

2. Make the pattern (auto-generated in Katagami)

With the Katagami pattern tool, you just enter the finished size and it drafts a seam-allowance-included pattern, tiled to print at actual size on Letter or A4.

1. Open the tool
   Open the pattern tool and choose “Fandom” → “Badge cover” from the tabs at the top.
2. Enter the size
   Enter the badge diameter, the depth allowance and the hanging loop. Presets cover 44, 57, 75 and 100 mm badges.
3. Set the seam allowance
   Use the slider at the bottom (beginners: 1.0–1.5 cm / about 3/8–5/8 in).
4. Print
   Press “Print (actual size)”, then in the print dialog set Scale = 100% and turn “Fit to page” OFF. Check the 50 mm calibration box on the first guide sheet with a ruler.

3. Cutting the fabric

1. Measure the badge
   57 mm is standard, but 44, 75 and 100 mm are all common.
2. Trace the pattern
   On vinyl, mark only the outline with a permanent pen.
3. Cut the pieces
   One back (fabric), one front (vinyl), and a loop if you want one.
4. Get clips ready
   Pin holes stay in vinyl. Clips only.

4. Sewing

4-1. Finish the opening

1. Turn the straight edge of the vinyl under 5 mm and stitch. That is the opening the badge goes through.
2. Vinyl sticks to the presser foot. Without a Teflon foot, sew through a sheet of paper and tear it away.

4-2. Baste the loop

1. Fold the loop in four and topstitch.
2. Baste it to the top edge of the back piece.

4-3. Sew the two together

1. Place back and front right sides together and hold with clips.
2. Sew around, leaving the opening.
3. Unpicking leaves holes. Check the shape while it is only clipped.

4-4. Turn and finish

1. Turn through the opening.
2. Clipping the allowance gives a cleaner curve.
3. Slip the badge in and check the fit.

✏️ No pins in the vinyl. The holes never close and the cover tears from them. Clip it, check the shape before sewing so you never have to unpick, and lengthen the stitch to about 3 mm so there are fewer holes to begin with.

5. Tips & variations

• 0.3 mm is the sweet spot: thinner buckles, thicker will not feed through a domestic machine.
• Pair it with the ita bag: badges can be displayed without scratching.
• Long stitch length: 3 mm keeps the vinyl strong.