Want to learn how to make a bean bag (and a proper bean bag chair)? This consolidated guide walks you through both projects in one place, from choosing fabric to sewing a durable liner and fitting a zipper. You’ll end up with a comfy, custom seat that matches your home—and you’ll understand how to adjust the shape, size and firmness so it actually feels good to sit in.
Prefer to skip the sewing and get straight to relaxing? Explore our ready-made bean bag chairs for indoors, outdoors and family spaces.
What You’ll Make in This Guide
This tutorial covers two popular DIY builds:
- A classic round “bean bag” (simple, beginner-friendly, great for kids’ rooms and reading corners)
- A structured bean bag chair (panelled design with better back support and a more “chair-like” sit)
Both versions use the same fundamentals: strong seams, a removable outer cover, and an inner liner that keeps the fill contained.
Before You Start: Size, Shape and Where It Will Live
Start by choosing where your bean bag will be used. A lounge room seat needs tougher upholstery fabric than a kids’ bedroom, and poolside use calls for true outdoor-grade materials. If you’re making an outdoor version, read the best materials for outdoor bean bag chairs.
Next, pick a size:
- Small / kids: easy to move, quick to sew, great for reading and gaming
- Medium: versatile, suits most living areas
- Large / lounger: the “sink-in” feel, perfect for movie nights and naps
Materials and Tools Checklist
Gather your supplies first so you can sew in one go.
- Outer cover fabric: 4–6 metres of durable upholstery fabric (amount depends on your pattern and size)
- Inner liner fabric: heavy calico, muslin, drill or another tightly woven fabric
- Heavy-duty zipper: 56 cm (22”) is common for chair patterns (or longer for large bags)
- Thread: strong polyester thread
- Sewing machine (recommended) + needles suitable for upholstery fabric
- Fabric scissors or rotary cutter
- Measuring tape / ruler
- Pins or clips
- Chalk or fabric marker
- Iron (helps seams sit flat and improves finish)
About filling: If you’re unsure about safety, see is polystyrene safe and environmentally friendly?
Fabric Choices That Actually Work
DIY bean bags fail for two main reasons: weak fabric and weak seams.
- Best all-round indoor fabrics: upholstery canvas, denim, twill, heavy cotton blends
- Kid-proof choices: tightly woven fabrics with some texture (they hide marks and scuffs)
- Outdoor fabrics: performance fabrics designed for UV and moisture (see our outdoor fabric guide)
If you’re building an outdoor bean bag, olefin is a popular choice because it’s designed for sun, moisture and frequent cleaning. Here’s a deeper dive: what is olefin fabric?
Step-by-Step: How to Make a Simple Round Bean Bag
This is the easier project and a great starting point for beginners. The basic idea is two circles (top and bottom) plus a side panel (a long rectangle that forms the “wall” of the bag). You’ll create an inner liner and an outer cover, each with a zipper opening so you can remove and wash the cover.
1) Choose your dimensions
A common medium size uses a diameter around 90–100 cm, but you can scale up or down.
2) Cut your pieces
- Cut two circles (top and bottom) in your outer fabric
- Cut one side panel rectangle in your outer fabric (length = circle circumference + seam allowance)
- Repeat the same pieces in liner fabric
Tip: Add seam allowance (about 12 mm / ½”) to every edge. Mark notches at quarter points on the circles to help you align pieces while sewing.
3) Sew the side panel into a loop
With right sides together, sew the short ends of the side panel to form a loop. Press the seam open.
4) Attach the circle
Pin the side loop to the circle, matching your quarter-point notches. Sew slowly, easing the fabric around the curve. Repeat for the other circle, leaving an opening where the zipper will go.
5) Add the zipper opening
Install a heavy-duty zipper on a straight section (many people add a short straight seam into the side panel or use a zipper panel). For kids’ use, consider a zipper style that can be secured or covered. Then repeat the same steps for the inner liner.
6) Assemble cover + liner
Insert the liner into the outer cover. When it’s time to fill, fill the liner—not the cover—then close both. If you need a quick method for topping up later, see how to fill a bean bag in 5 minutes.
Step-by-Step: How to Make a Bean Bag Chair With Panels
A bean bag chair feels more supportive because it uses multiple panels that create a higher back and a stable sitting shape. The common pattern uses six side panels plus a top and a bottom piece. You’ll make an outer cover and an inner liner.
1) Make or trace your pattern
Work from a reliable pattern or draft one carefully. For the classic panelled chair shape, you’ll typically need:
- 6 side panels (outer) + 6 side panels (liner)
- 1 top piece (outer) + 1 top piece (liner)
- 2 bottom pieces (outer) + 2 bottom pieces (liner) so you can insert a zipper along the straight seam
2) Cut accurately (this matters)
Accuracy is the difference between “homemade” and “good.” Cut cleanly, mark each panel, and keep your pieces stacked so they stay identical. Press fabric first if it’s creased—creases become measuring errors.
3) Sew the bottom and insert the zipper
Pin the two bottom pieces together along the straight edge and baste the seam. Press open. Place your zipper right-side down along the seam line and stitch both sides using a zipper foot. Keep the zipper open while sewing so you can turn the cover later.
4) Join the side panels
Sew the six side panels together (right sides facing) to form the chair “tube.” Double-stitch or reinforce seams if the chair will be used daily or by kids. Press seams flat.
5) Attach top and bottom
Pin the top piece to the side tube and sew. Repeat for the bottom piece. Turn the cover right-side out through the zipper opening and top-stitch along seams if you want a cleaner finish and extra durability.
6) Make the inner liner
Repeat the same process using liner fabric. The liner should be the same size as the cover. Strong seams here are essential because this layer holds the fill. If you want to understand when a liner helps (and when it’s optional), see the advantages and disadvantages of liners.
7) Assemble and test the “sit”
Place the liner inside the cover. Before final filling, do a quick “shape test” by lightly stuffing the liner with towels or blankets. This helps you confirm the height and back support without committing to a full fill.
Alternative: A Simple Cube Bean Bag Chair
If curved panels feel intimidating, make a cube: cut six identical squares, sew five together, add a zipper on the last seam, then repeat for the liner.
Tips to Make Your DIY Bean Bag Last
- Use strong seams: a 12 mm seam allowance plus reinforced stitching reduces blow-outs.
- Use an inner liner: it keeps the fill contained and makes washing the cover easier.
- Choose washable fabrics: especially for kids, pets and high-traffic rooms.
- Think about safety: if children are present, use zipper covers or remove zipper pulls so little hands can’t access the fill.
- Don’t overfill: overfilled bags feel hard and put stress on seams; slightly underfilled bags feel more comfortable and mould better.
Want the Bean Bag Look Without the Sewing?
DIY is fun, but it’s not for everyone. If you’d rather enjoy the comfort without the measuring and stitching, browse our bean bag chairs and our bigger, “sink-in” styles in large bean bags.
Quick Project Add-On: A Bean Bag Heating Pad
If you’ve enjoyed this project and want something smaller, try making a bean bag heating pad. It uses similar sewing skills, requires less material, and makes a practical DIY gift.
Conclusion
Start simple, focus on strong fabric and seams, then move up to the chair pattern when you’re ready. If you want comfort on day one, explore our ready-made bean bag chairs.
