Sewing an All-In-One (AIO) Diaper
Materials Needed:
Barrier fabric
OUTER
(PUL is most common, heavy fleece is sometimes used. Wool isnot appropriate for an AIO-style, as it must be handwashed)
Soft fabric
INNER
(stay-dry microfleece shown, other popular fabrics are suedecloth,flannel, velour, and silk)
Absorbant
CORE
(microfiber shown, also hemp, cotton, bamboo, etc)
ELASTIC
(I recommend stretchrite brand, I use ¼” for the legs on all sizes, as well asthe waist on smalls. I prefer 5/8” for the waistband on larger sizes, but ¼” works ok too.)
CLOSURES
(I use touchtape, other options are aplix, industrial velcro, and snaps)
Some things to think about when choosing materials:
What will this diaper be used for? How long will the baby wear it between changes (howabsorbent does it need to be?) Are sensitive skin/reactions an issue? (Some kids react to syntheticfabrics, others react to staying wet). What materials can I afford? (organic bamboo velour retailsat $19/yd, whereas cotton flannel is $3/yd)Here are the materials I prefer, and why:PUL (1 or 2ml, either is fine—1ml is slightly more flexible, and is generally cheaper, however Ifeel that 2ml holds up to more use/abuse, particularly for toddlers)Microfleecekeeps the skin dry by wicking moisture through to the absorbent core. Because itdoes not absorb any moisture, it won’t wick it onto the outer fabrics (fewer leg leaks). It is alsovery soft. Alternatively, I like velour which is not ‘stay-dry’ but tends to feel more dry becauseof the height of the fuzz. It stays soft forever, whereas microfleece will pill a bit after repeatedwashings. The downside to these fabrics is that they are both stretchy, which makes them a littleharder to sew.Microfiber dries quickly, and is VERY thirsty. It is available inexpensively as ‘auto care cloths’at places like Costco.SO, you have your fabrics, you have your pattern, you’ve cut everything out, now you’re readyto sew!If at any point in the process you have questions, please feel free to contact me viahttp://.lilbees.etsy.comor brightonwoman@yahoo.com
You may feel the intense desire to nuzzle your microfleece or velour. I recommend doing thisnow, because once the diaper gets used, you’ll never get another chance.
STEP 1—attaching the core
Lay out the core on the wrong side of theinner. It should be centered between thesides (around ¾-1” from edge) and roughlycentered front-to-back as well (about 1 ½”from edge). Sew all the way around, takingcare not to pucker the inner (which will probably stretch). It may end up not quitestraight. That’s normal and ok—it won’tshow later, and this is a poop-catcher, after all!
wrong side
I use 3 layers microfiber, but 2 layers is probablysufficient for newborn/small diapers.Core size in inches (I usually use 1 large pieceand tri-fold it)S—12 long x 4ish wide (12x12 trifold)M—14 long x 5 wide (14x16 trifold)L—16 long x 5ish wide (16x16 trifold)
right side
STEP 2 –sewing the sides together
Lay the inner and outer together,right sides together (the shiny side of the PUL is the wrong side). Nomatter how carefully you cut, they probably will not line up perfectly because the fabrics both stretch a bit—the most important place tomatch up is across the top back, andto have the centers in alignment.
Always sew with the inner side up!!
(otherwise the PUL willstick to your presser foot and will notmove through the machine)
Use 5/8” seam allowance across back, and 1/4” (edge of presser foot) everywhere else. Be sureto leave an opening across the front for turning it right-side-out (I leave it the same width as thecore—I have little hands though, so if you have larger hands you may want to leave it wider)The fabric will probably stretch a bit. Puckers/tucks are ok in the areas that will have elasticanyway, so just pinch the fabric to those places if you can’t get it to lay flat. (and yes, the fuzzfrom the microfiber will get everywhere!)
front openingseam allowance change
This is a good time to check the height of your tabs.Lay one against the other to verify that they are thesame width (top to bottom). If your back seam slanteda little they may be off. With your first few diapersyou may also want to lay on a piece of the velcro toverify that the tab is wide enough to fit it. This patterndoes not have a lot of room to spare in that regard, butyou don’t need much either. Of course the diaper willstill work, but it will look kinda funny if the tabs aredifferent sizes. If one is bigger than the other, it’s easyat this stage to pick out an inch or two of stitching andeven them up.
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