How to make a passport case

1. Materials & tools

Materials (2 people)

• Main fabric (canvas, faux leather or heavy cotton) — about 50 × 40 cm (20 × 16 in)
• Lining fabric (light cotton) — the same amount
• Pocket fabric — about 40 × 30 cm (16 × 12 in)
• Firm fusible interfacing — for the main fabric
• Optional: a snap or elastic closure

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 “Bags” → “Passport case” from the tabs at the top.
2. Enter the size
   Enter the passport width and height, the contents thickness and the card pocket height. Presets cover 1 person, 2 people and a family of 4.
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 contents
   Measure a passport, and stack everything you intend to carry to get the thickness.
2. Trace the pattern
   Trace the body, the card pocket and the ticket pocket, and mark the center fold.
3. Cut
   Cut the body in main and lining, one card pocket and one ticket pocket, and fuse interfacing to the main fabric.

4. Sewing

4-1. Make the pockets

1. Turn the top edge of each pocket under twice and stitch. Do this before they go near the case.

4-2. Attach the pockets

1. Lay the card pocket on one side of the center fold on the lining, and the ticket pocket on the other.
2. Stitch the card pocket vertically into slots, about 6 cm (2⅜ in) each. Backstitch at the top of every line.
3. Making the ticket pocket full height lets a passport slot in behind its cover, which holds it open at the photo page.
4. Baste the lower and side edges within the seam allowance.

4-3. Sew the layers together

1. Place main and lining right sides together and sew around, leaving a 12 cm (5 in) gap.
2. Trim the corners, turn, press and topstitch all the way around.

4-4. Fold and close

1. Fold at the center and press.
2. Load it and fit the snap or elastic with everything inside.

✏️ Measure the thickness for real. One passport is about 5 mm; four passports with boarding passes and cards comes to nearly 2 cm. Leave that out and the case is held open by its own contents.

5. Tips & variations

• Add a pen loop: you will need a pen for landing cards, and there is never one to hand.
• Faux leather: no interfacing needed, but sew it once — the needle holes are permanent.
• Also a passbook case: at other sizes this is a passbook or record book case.