How to Sew with Outlet PUL Fabric for Diapers
By Thirsties Baby | Published: 2026-10-19
Category: How-to Guides
Learn practical steps for sewing with outlet PUL fabric, including needle choice, seam sealing, and care tips to make durable DIY cloth diapers.
Quick Answer
To sew with outlet PUL fabric for diapers, use a ballpoint or stretch needle, a walking foot, and polyester thread, and seal your seams with a hot iron or seam tape to keep them waterproof.
Why Outlet PUL Fabric Works for Diaper Sewing
Outlet PUL fabric is the same polyester laminate used in commercial cloth diapers, just offered at a discount. It has a waterproof layer that makes it ideal for diaper covers and wet bags, and because it's sold by the yard, you can buy exactly the amount you need for your project.
One trade-off: outlet fabric may have slight color variations or minor imperfections, but these rarely affect performance. Always inspect your fabric when it arrives and plan your pattern pieces to avoid any flawed areas.
Step-by-Step Sewing Process
- Prepare your fabric and pattern: Wash and dry your PUL fabric before cutting to remove any factory residue and reduce shrinkage. Then, lay out your pattern pieces, ensuring the waterproof side faces the right direction. Always pre-wash PUL fabric to avoid post-sewing shrinkage.
- Choose the right needle and thread: Use a ballpoint or stretch needle (size 75/11 or 90/14) to prevent skipped stitches, and pair it with polyester thread for durability. Avoid cotton thread, which can rot over time. Test your stitch on a scrap piece first to adjust tension and stitch length.
- Use a walking foot and adjust stitch settings: Attach a walking foot to help feed the slippery laminate evenly. Set a straight stitch length of 2.5-3.0 mm and reduce presser foot pressure if your machine allows. A walking foot prevents shifting and puckering on laminate fabric.
- Sew your seams and seal them: Sew your pieces together with the waterproof side facing up. After sewing, seal the seams by pressing them with a hot iron (using a pressing cloth) or by applying seam tape to the inside to maintain waterproof integrity. Sealing seams is critical—unsealed needle holes can leak.
- Finish edges and care for your project: Trim excess fabric and finish raw edges with a zigzag stitch or bias binding. To care for your finished diaper, wash in cold water and hang to dry; avoid high heat in the dryer, which can break down the laminate. Proper care extends the life of your DIY cloth diaper.
Outlet PUL Fabric Options
- Outlet Polyester Laminate Fabric By the Yard - Food Safe - 58" Wide - O2 Revival: This outlet offering features O2 Revival polyester laminate fabric by the yard, a food-safe material that is 58 inches wide. The wider 58-inch width gives you more layout flexibility, so you can cut larger pieces like diaper covers or wet bags in one go.
Outlet Polyester Laminate Fabric By the Yard - Food Safe - 58" Wide - O2 Revival - Outlet Polyester Laminate Fabric By the Yard - Food Safe - 54" Wide - Rainbow: This outlet offering features Thirsties Baby polyester laminate fabric by the yard, available in a cheerful rainbow print. The fabric is 54 inches wide and is food safe. The food-safe finish means your finished projects can safely come into contact with food, making this a versatile choice for bibs or changing pads.
Outlet Polyester Laminate Fabric By the Yard - Food Safe - 54" Wide - Rainbow
