How to make a diaper cover

1. Materials & tools

Materials (one cover, 3–6 months)

• Main fabric (laminate, PUL or cotton) — about 50 × 50 cm
• Flat elastic, 6 mm — about 40 cm for the waist, 16 cm × 2 for the legs
• Snap fasteners — 2 pairs
• Sewing thread (a Teflon foot helps with laminates)

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 “Baby” → “Diaper cover” from the tabs at the top.
2. Enter the size
   Enter the waist, the rise, the crotch width and the ease. Presets cover newborn, 3–6 months and 6–12 months.
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. Trace the pattern
   Lay the pattern on the wrong side and trace both lines. The center line is the fold.
2. Cut the pieces
   Cut the front on the fold and the back on the fold. Pins leave permanent holes in laminate — use clips.
3. Transfer the notches
   Mark the side notch where the crotch curve begins.
4. Finish the edges
   Zigzag the allowances if you are using cotton. Laminate does not fray.

4. Sewing

4-1. Sew the crotch

1. Place front and back right sides together and sew the crotch seam.
2. It is curved, so clip the allowance to stop it pulling.
3. Clipping breaks the waterproof layer on laminate — trim the allowance to 5 mm instead.

4-2. Elastic at the legs

1. Fold each leg edge by 1 cm, then 1 cm again, and stitch, leaving a 2 cm gap.
2. Thread the elastic and secure at about 16 cm a side.
3. Keep it loose — two fingers should slide under easily.

4-3. Elastic at the waist

1. Fold and stitch the waist the same way.
2. Thread elastic through the back only. A front that does not stretch is easier to fasten.
3. About 85% of the waist measurement is the guide.

4-4. Add the snaps

1. Fit two pairs of snaps at each side.
2. Hold the cover against the baby and decide the positions before you set them.
3. Two rows lets you take it in as they grow.

✏️ Do not tighten the elastic. A diaper cover is worn all day, and anything snug leaves marks. Two fingers should slide under the leg elastic easily. If it leaks at that tension, the diaper underneath usually needs adjusting rather than the cover.

5. Tips & variations

• Waterproof fabric: laminate or PUL for going out. Use clips, not pins.
• Or plain cotton: at home, cotton is fine and breathes far better.
• Two rows of snaps: fitting both rows lets the cover shrink as the baby grows.