How to Make Cloth Diapers

Co-authored by Denise Stern

Last Updated: May 13, 2022

Diapers, or nappies, are mostly made of a combination of plastic and cotton. It has been estimated that the average baby goes through 6,000 diapers before being potty trained. Before disposable diapers gained popularity in the last few decades, most families made or bought reusable cloth diapers. Today, cloth diapers are gaining ground because they can be reused and this will save your family money. There are a number of patterns you can find to sew cloth diapers, from simple to elaborate designs, but you can make a cloth diaper using cloth, a sewing machine and a little time.

Part 1

Part 1 of 4:

Creating Inserts for Cloth Diapers

1
Gather your materials. Making cloth diapers is not difficult, but you will need some special tools and materials to do it. To create your own cloth diapers, you will need:^{[1]
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- flannel material
- microfiber towels
- precision knife
- cutting mat
- sewing machine
- serger (optional)
2
Cut your flannel to the same dimensions as the microfiber towels. Lay one of your microfiber towels over your flannel fabric and then cut the flannel so that it is the same size as your microfiber towel. You will need two pieces of flannel material to go on the outside of the microfiber towels, so cut out two pieces of flannel.^{[2]
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3
Layer the materials. Next, lay down a piece of flannel material pattern side down. Then, lay down three microfiber towels over this piece of flannel. Then, complete the fabric sandwich by placing another piece of flannel pattern side up on top of the microfiber towels.^{[3]
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- Pin the materials together in several places to keep them in place when you sew them. Make sure that the pins go through all of the layers of material.
4
Sew across the layers. Next, sew across the layers of fabric that you just pinned together. Sew several parallel lines across the fabric to keep it in place. Sew slowly to ensure that you do not end up with any bumps or uneven spots.^{[4]
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- Make sure to avoid the serged edges of the microfiber towels. They may break your needle if you try to sew through them.
- Remove the pins as you sew.
5
Cut off the outer edges of the microfiber and flannel square. Sewing through already serged edges may break your needle. To avoid breaking your needle on the serged edges of the microfiber towels, you will need to cut off the outer edges of your microfiber and flannel material square.^{[5]
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- Use your cutting mat and precision knife to cut off these edges.
- You can also use a ruler or other straight edge to ensure that that you cut the fabric evenly.
6
Measure and cut the squares into four-inch wide strips. Use a ruler to measure the squares into four-inch wide strips. Then, cut the pieces into these strips. You should be able to create three strips out of each square. Each of these strips can be used as a diaper insert.^{[6]
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7
Serge across outer edges of the strips. It is important to serge or zigzag stitch the edges of the strips to prevent them from fraying and to make them last longer. Take your strips one at a time and serge across the edges or use a zigzag stitch if you do not have a serger.^{[7]
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- If you have cloth diapers and just needed some inserts, then your project is finished! However, if you need the outer cloth part of the diapers, then you will need to make these next.

Part 2

Part 2 of 4:

Cutting and Pinning Fabric for Fitted Diaper Covers

1
Choose your fabrics. Flannel cloth diapers are popular because the fabric is soft, but you can also choose terry, twill or a soft jersey or cotton blend. You will need a fabric for the outside and a fabric for the inside, so buy at least a yard (0.9 m) of each.
- To save money, you can also use old flannel sheets or shirts instead of buying fabric by the yard.
2
Find a pattern and print it out. If you search the internet for "cloth diaper pattern," you should find many free options to choose from.^{[8]
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Research source} However, you can also purchase a cloth diaper pattern. The pattern will look similar to a large spool of thread or hourglass.
- Another pattern option is to buy a cloth diaper and trace it onto a pattern made of thick paper, like butcher paper.
3
Trace the pattern onto your cloth. Use a light marker or fabric marker to trace your pattern onto the fabric and then cut it out. Repeat this process so that you have two cloth diaper shapes. One will go on the outside and the other will go on the inside of the diaper.
4
Pin one of the inserts to the center of the two pieces. Center one of the soaker pad inserts on the middle of one of the cloth diaper pieces so that it is extending from one end of the diaper piece to the other. Then, lay your other piece of fabric over this one and pin the diaper piece into place.
5
Align all of the edges. Pin the layers into place around the edges of the cloth diaper and through the soaker pad insert. Make sure that all of the edges are even.

Part 3

Part 3 of 4:

Sewing the Pieces Together

1
Stitch the soaker pad onto the fabric. Take the cloth diaper to the sewing machine and sew a straight stitch around the outer edges of the pad to secure it in place. Remove the pins as you go.
2
Sew the outside of the diaper. Next, sew a straight stitch 1/4 to 1/2 inch (0.6 to 1.3 cm) from the outside of your layers, making sure to back stitch at the ends.
- If you do not want the raw edges of your material visible, then you can fold over the edges as you sew, but it is not necessary. A little extra fabric on the outer edge of the seam is okay and may even offer some extra leak protection.
3
Fold the diaper lengthwise. Mark the places where you want the 3/8 inch (1 cm) sew-on elastic to go. You will need some elastic at the top backside of the diaper and the edges of the legs. The elastic should stop about two inches (5 cm) from both ends of the diaper at the top and legs.
4
Pin the elastic on the lines you have just marked. The elastic will need to be even with the straight stitch that you just made on the legs and backside of the diaper.
5
Sew the elastic on the top end with a small straight stitch. When you have decided where to place your elastic, go over the elastic with a large zig-zag stitch. Back stitch a couple of times also.
- It is important to go over the elastic multiple times to ensure that it will stay in place.
- Make sure that you tug on the elastic as you sew to ensure that it will have the desired cinching effect around the waist.
6
Stitch the elastic on the outer edges of the inside of the legs. Do not add elastic at the bottom of the diaper where you will pull it over the baby's stomach. The elastic should pull the fabric in when you are done.
- As you sew on the elastic, make sure to stretch it slightly to ensure that it will pull in the fabric around the legs and back of the diaper.
- Elastic around the baby's legs and bottom will help keep in leaks.
7
Cover the elastic. To avoid having elastic right up against your baby's skin, you will need to sew your third diaper cutout over the inside of the diaper. Line up the fabric with the inside of the diaper and then pin it into place. When you are ready, sew through the outer edges of this piece, the elastic, and the other cloth diaper pieces.
- Make sure that you stretch the elastic pieces as you go.

Part 4

Part 4 of 4:

Adding the Velcro

1
Cut out your Velcro pieces. Cut a length of 1 1/2 inch-wide (3.8 cm-wide) Velcro. You will need enough Velcro so that it goes most of the way across the bottom outside edge of the front of your cloth diaper. Then, cut two small squares of the opposite side of the Velcro, also known as the hook side.
- It is best to make the hook side of the Velcro your long piece because this piece can be irritating to your baby's skin.^{[9]
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  Research source} By placing the hook side on the outer front side of the diaper, it will be less likely to come into contact with your baby's skin.
2
Pin your Velcro strip onto the diaper. Pin the length of Velcro into place along the bottom outside edge of the diaper. This will be the front of the diaper.
3
Sew the strip into place. After you have pinned the Velcro where you want it to go, use a zigzag stitch around the outside of the Velcro strip to attach it to the diaper. Remove the pins as you sew.
- Make sure to backstitch a couple of times to be certain that the Velcro is in place.^{[10]
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4
Secure the two Velcro squares. Next, pin the two Velcro squares to the inside edges of the top of the diaper using pins. This is the back piece of the cloth diaper, which will wrap around your baby's waist and connect with the front piece to secure the diaper.
5
Use a zig zag stitch around the squares to secure them. To secure the square pieces, use a zigzag stitch again. Remove the pins as you go.
- Backstitch the squares a couple of times as well to be sure that the Velcro stays in place.^{[11]
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6
Use the cloth diaper the next time your baby needs a change. The diapers are now finished and you can use them as soon as you need them!

Community Q&A

Question

Can my baby tell the difference between cloth and disposable diapers?

Community Answer

Probably, but not to a degree where you should be concerned.
Question

What if the diaper is for me (an adult)? Would I do the same thing, just make it bigger?

Community Answer

Yes. If the diaper is for you, and you are larger than an infant, just make the measurements larger.
Question

Where do I get a pattern to cut the cloth?

Community Answer

At a fabric store or online. JOANN Fabrics is a good place to find many different styles and patterns.