Making your own bolster pillow gives you complete control over size, firmness, and fabric choice, and the sewing is straightforward enough for beginners. A basic bolster cover requires only straight seams and a zip insertion, making it one of the simplest pillow projects you can tackle. Whether you want a custom size that shops do not stock or a fabric that matches your existing decor perfectly, here is a step-by-step guide to making bolster pillows at home.
Materials You Need
For a standard bolster (20 cm diameter, 60 cm long), you need: 70 cm of fabric at least 115 cm wide, a 55 cm zip, matching thread, a bolster insert or filling material, and basic sewing tools (machine, scissors, pins, tape measure). Choose medium-weight fabric like cotton twill, linen, or upholstery-weight cotton. Lightweight fabrics (voile, thin cotton) stretch and sag around the cylindrical form, losing the crisp shape that makes bolsters look polished.
For the insert, you have three options. Buy a pre-made bolster insert from a haberdashery or online retailer (cushion insert suppliers often stock bolster forms). Make your own insert from calico or muslin filled with polyester stuffing. Or skip the inner cover and stuff the outer cover directly if using a sturdy, washable fabric.
Cutting the Fabric
A bolster cover has three pieces: one rectangle (the body) and two circles (the ends). Calculate the rectangle dimensions as follows: width equals the circumference of the bolster plus 3 cm seam allowance (for a 20 cm diameter bolster, circumference is roughly 63 cm, so cut the rectangle 66 cm wide). Length equals the bolster length plus 3 cm (60 cm bolster needs a 63 cm long rectangle).
For the end circles, the diameter equals the bolster diameter plus 3 cm seam allowance (23 cm diameter circles for a 20 cm bolster). Cut two circles. Use a plate or compass to draw accurate circles, as wobbly circles create puckered ends that look amateurish.
Oubonun Throw Pillow Inserts
Sewing the Body
Fold the rectangle in half lengthways with right sides together, matching the long edges. Pin and sew a 1.5 cm seam along the long edge, but leave a gap in the centre for the zip. The zip opening should be roughly 5 cm shorter than the zip teeth length. Press the seam open, including the unsewn zip opening.
Pin the zip face-down over the pressed-open seam allowance, centred on the opening. Sew the zip in place using a zip foot on your sewing machine, stitching close to the zip teeth on both sides and across both ends. Open the zip partway before attaching the end circles so you can turn the cover right side out later.
Attaching the End Circles
Pinning circles to cylinders is the trickiest part of bolster construction. Start by dividing both the circle edge and the tube opening into quarters, marking with pins. Match the quarter marks and pin, then fill in between. The fabric will want to pucker at the curves, so use many pins (every 2 to 3 cm) to distribute the ease evenly.
Sew each circle to the tube with a 1.5 cm seam, moving slowly around the curve and removing pins just before they reach the needle. Clip the seam allowance of the circle every 1 to 2 cm after sewing (snip small triangles, taking care not to cut the stitching). Clipping allows the curved seam to lie flat when turned right side out. Turn the cover through the zip opening and press.
Filling Options
Polyester stuffing (hollowfibre) is the most accessible filling for homemade bolsters. Pack the filling firmly and evenly, working from both ends toward the centre. Under-filling creates a saggy bolster that does not hold its cylinder shape. Over-filling creates a hard, lumpy surface. Aim for firm enough to maintain shape when stood on end but soft enough to compress slightly when squeezed.
For a firmer bolster (yoga or support use), wrap a foam cylinder in a thin layer of polyester batting before inserting it into the cover. Upholstery foam suppliers sell foam in cylinder form or can cut cylindrical shapes to order. Foam bolsters maintain their shape indefinitely compared to fibre-filled bolsters, which flatten over time. For information on how different fills age, our pillow care guide covers maintenance for every material.
Oubonun Throw Pillow Inserts
Alternative Construction Methods
No-Sew Bolster
Wrap a foam cylinder or rolled towel in fabric, tucking the excess into each end like wrapping a Christmas cracker. Secure the gathered ends with ribbon, cord, or rubber bands hidden under decorative ties. The result lacks the tailored finish of a sewn bolster but works perfectly for casual use and costs almost nothing if you use fabric scraps.
Gathered-End Bolster
Instead of sewing flat circles, cut the rectangle longer than the bolster (add 15 to 20 cm per end). Sew the long seam with a zip as normal, insert the bolster form, then gather each fabric end with a drawstring, ribbon, or elastic. Gathered ends create a softer, more relaxed look than flat panels. Add a covered button or tassel over the gathered centre for a finished detail.
Repurposed Bolsters
Old throw pillows that have gone flat can be rolled tightly and secured with a few stitches to create a bolster insert. Two standard-size flat pillows rolled together and wrapped in a muslin sleeve create a bolster of approximately 18 cm diameter. Old towels rolled and stuffed into a tube cover make serviceable bolster inserts for everyday use.
For ready-made bolster options, explore our bolster pillow recommendations. If you enjoy DIY pillow projects, the same sewing skills apply to making custom cushion covers and floor cushion covers.
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