A780 Washable Newborn Nappy

How to Sew a Washable Newborn Nappy

Make a soft reusable newborn nappy from absorbent terry towelling and flannelette. The design features a built-in three-layer insert, elasticated leg openings and back waist, and adjustable hook-and-loop tabs at the front.

The nappy is sewn from two shaped terry-towelling body pieces. The absorbent insert is attached to the inside before the body layers are sewn together, turned right side out and topstitched.

What You Will Need

Materials

• 100 × 40 cm terry towelling
• 30 × 15 cm flannelette
• 25 mm wide hook-and-loop tape
• 6 mm elastic
• Matching sewing thread

Equipment

• Fabric scissors
• Dressmaking pins or clips
• Sewing machine
• Hand-sewing needle
• Overlocker, if available
• Fabric-marking pen or chalk
• Printer for the pattern templates

Cutting List

Nappy Body

• Cut 2 nappy body pieces from terry towelling

Absorbent Insert

• Cut 2 insert pieces from terry towelling
• Cut 1 insert piece from flannelette

Elastic

• Cut 3 lengths of elastic, each measuring 12 cm

Hook-and-Loop Tape

• Cut 1 length of loop tape measuring 12 cm
• Cut 2 pieces of hook tape measuring 3 cm each

Understanding the Pattern Pieces

The nappy pattern is divided across two printable pages and is designed to be placed on the fold.

The pattern markings show:

• Where to position and sew the absorbent insert
• Where to attach the waist and leg elastic
• Where to leave the turning opening
• Where to attach the hook-and-loop tape
• The fabric fold line

Page 3 also shows how the finished components relate to one another. The insert is centred vertically on the wrong side of the inner nappy piece, the long loop tape sits across the front outer panel, and the two small hook tabs sit on the outer face of the waist wings.

Prepare the Fabric

Wash and dry the terry towelling and flannelette before cutting. This allows for any initial shrinkage and helps ensure the completed nappy retains its intended size after laundering.

1. Press the fabric flat without crushing the towelling pile.
2. Print and assemble the pattern pieces.
3. Place the nappy pattern on the fabric fold as marked.
4. Trace the pattern and transfer every construction mark.
5. Cut two matching nappy body pieces.
6. Cut the three insert layers.

Sew the Absorbent Insert

Layer the Insert

Stack the three insert pieces in this order:

1. Flannelette
2. Terry towelling
3. Terry towelling

Align all edges and pin or clip the layers together.

Finish the Insert Edges

Sew around the complete outside edge using either:

• An overlocker
• A wide zigzag stitch
• An overcasting stitch

The edge finish should secure all three layers and prevent the towelling from fraying during washing.

Attach the Insert to the Nappy

1. Place one terry-towelling nappy piece with its wrong side facing upwards.
2. Position the completed insert over the marked rectangular area.
3. Make sure the flannelette side of the insert is touching the wrong side of the nappy body.
4. Pin the insert securely at several points.
5. Sew around the insert with a straight stitch, keeping close to the finished edge.

Backstitch at the beginning and end so the insert remains securely attached through repeated washing.

Join the Nappy Body

1. Place the two nappy body pieces right sides together.
2. Align the waist wings, leg curves, front and back edges.
3. Pin or clip around the complete perimeter.
4. Leave the marked turning opening unsewn.
5. Stitch around the nappy using the pattern seam allowance.

Sew slowly around the curved leg openings and rounded wing ends for a smooth finished shape.

Add the Elastic

The pattern uses three 12 cm lengths of 6 mm elastic:

• One along the back waist
• One around the first leg opening
• One around the second leg opening

Sew the Elastic Into the Seam Allowance

1. Position one elastic length between the marked start and finish points.
2. Secure the first end firmly inside the seam allowance with several stitches.
3. Stretch the elastic gently until it reaches the second marked point.
4. Sew along the elastic while keeping it stretched.
5. Secure the second end firmly.
6. Repeat for the remaining elastic sections.

Tips for Sewing Elastic

• Use a medium-width zigzag or a stretch stitch.
• Lower the presser-foot pressure if the towelling bunches.
• Stretch the elastic rather than the fabric.
• Reinforce both ends so the elastic cannot pull free.
• Do not cut the elastic shorter unless the fit has been tested.

Turn and Close the Nappy

1. Trim bulky seam allowances where necessary, taking care around the elastic attachments.
2. Clip the seam allowance around inward curves without cutting through the stitching.
3. Turn the nappy right side out through the marked opening.
4. Gently push out the waist tabs and rounded edges.
5. Fold the raw edges of the opening inward.
6. Pin or clip the opening closed.
7. Sew the opening securely by machine or with a concealed hand stitch.

Topstitch the Nappy

Topstitch approximately 1 cm inside the outer edge around the nappy.

1. Begin on a straight section.
2. Sew slowly around the complete nappy.
3. Stretch the elasticated leg and waist sections flat as they pass under the presser foot.
4. Keep the topstitching clear of the elastic.
5. Backstitch securely at the end.

The topstitching closes the turning opening, stabilises the edges and helps stop the elastic from rolling inside the nappy.

Attach the Hook-and-Loop Fasteners

Prepare the Tape

Round the corners of every hook-and-loop piece before sewing. Rounded edges are less likely to feel sharp or scratch the baby’s skin.

Attach the Loop Tape

1. Position the 12 cm loop tape across the outside front of the nappy, using the placement marking on the pattern.
2. Pin or hold it securely in place.
3. Sew around all four edges using a short straight stitch or narrow zigzag.
4. Reinforce the beginning and end of the seam.

Attach the Hook Tabs

1. Position one 3 cm hook piece on the outer side of each waist wing.
2. Check the orientation so the tabs fasten onto the front loop strip when wrapped around the baby.
3. Sew securely around all four edges of each tab.

For additional adjustability, sew a second strip of loop tape beneath the first front strip.

Check the Finished Nappy

1. Check every elastic attachment.
2. Check that the insert is firmly secured.
3. Check the turning opening and perimeter topstitching.
4. Check all hook-and-loop edges for rough corners.
5. Remove loose threads.
6. Wash the completed nappy before first use.

How to Fit the Nappy

1. Lay the open nappy beneath the baby.
2. Bring the front section up between the legs.
3. Wrap one waist wing across the front.
4. Fasten its hook tab to the loop strip.
5. Repeat with the second waist wing.
6. Adjust the tabs so the nappy sits securely around the waist and legs.

The nappy should fit closely enough to reduce gaps without leaving deep marks or restricting movement.

Fit Check

• The back waist should sit flat against the baby.
• The leg elastic should rest in the natural groin crease.
• The insert should remain centred between the legs.
• The hook tape should be fully covered by the loop tape.
• No rough fastener edges should touch the skin.

Fabric Alternatives

Choose absorbent, washable fabrics that are soft against delicate skin.

• Cotton terry towelling – absorbent, durable and closest to the original project.
• Bamboo terry – soft and absorbent, although it may dry more slowly.
• Hemp and cotton blend – highly absorbent and suitable for insert layers.
• Cotton flannelette – soft and useful as the insert-facing layer.
• Cotton velour – soft against the skin and suitable for an inner layer.
• Birdseye cotton – lightweight, absorbent and relatively quick drying.

Choosing Suitable Elastic

Use elastic designed to tolerate frequent washing. Soft knitted or swimwear elastic may be suitable where it maintains recovery without becoming rigid.

Avoid old elastic, exposed rubber or elastic that feels harsh against the fabric.

Care and Washing

Follow the care instructions for all selected fabrics, elastic and fasteners.

1. Remove solid waste before washing.
2. Close or cover the hook tabs so they do not catch.
3. Wash with a suitable laundry detergent.
4. Rinse thoroughly.
5. Dry completely before reuse.
6. Check the elastic and fasteners regularly for wear.

Avoid ironing directly over the elastic or hook-and-loop tape, as excessive heat may damage them.

Baby Safety

• Check the nappy fit at every use.
• Do not use exposed pins or detachable decorations.
• Keep hook tape away from the baby’s skin.
• Replace stretched elastic or damaged fasteners.
• Stop using the nappy if seams begin to open.
• Change wet or soiled nappies promptly.