This tutorial is designed so that you can sew your own newborn inserts for cloth diapers spending the least amount of money possible. This is why we have created three different styles of newborn inserts - #1 is a sandwich style insert using Zorb. #2 is a prefold style insert using Zorb. And #3 is a prefold style insert using all scrap material (this being the cheapest way to make an insert).
When I was in the planning stages of making these inserts for our little one I wanted to purchase some awesome material for the outside of the insert - bamboo interlock. Then once I figured out how much the fabric was going to cost + shipping, plus all the other things I wanted to purchase for our new baby, I decided to make these on the cheap. I already had the Zorb (purchased from www.Wazoodle.com) from making other projects. I found an old flannel sheet and some old 100% cotton T-shirts to use on the outside of the Zorb (Zorb is an interesting fabric - it is an interlining material that looks almost like cotton batting, it must be sandwiched and sewn between two layers of fabric or it will not hold up to repeated uses). If I were making these again, I would still use the Zorb, even if I had to purchase it just for making inserts because I really like how it performs. Please do not use cotton batting in place of Zorb, it might look similar but I promise you will not be happy with the results.
This tutorial is going to be a tad different from ones that I have posted in the past. Let me explain.... I keep a sewing binder. Whenever I create something, I keep a record of what I made, what materials I used, the pattern, etc. I slip each project's information page and pattern in a sheet protector and put it in my sewing binder, this way I can go back and make the project again if I want to. For these newborn inserts I scanned my notes and I will post them for you to view on google docs. This was much easier for me than trying to transfer all my notes to a word doc, then creating a PDF, then uploading them here, etc.
I have included some pictures that match up with the steps in my notes. Once you download the notes, the pictures will make sense.
Here is the old flannel sheet that I up-cycled
Variation #1 - Sandwich Style Insert using Zorb
|The finished insert|
Size comparison to a Huggies Newborn size diaper
Size comparison to a Huggies size 1 diaper
Size comparison to the pocket diaper we made using Ericksonand Co. tutorial - Diaper is set on the smallest setting
|Variation #2 - Step 3|
|Variation #2 - Step 4|
|Variation #2 - Step 5|
|Variation #2 - Step 6a|
|Variation #2 - Step 6b|
|Variation #2 - Step 7|
|Variation #2 - Step 8 - The Finished Insert|
Variation # 3 - Prefold Style Insert using Only Scrap Material
This insert is pretty much the same as variation #2, the difference is this one does not use Zorb, but only uses layered scrap material to make the absorbent layer. Follow the pictures for Variation #2 from step 1-4
|Variation #3 - Step 6|
|Variation #3 - Step 7b|
|Variation #3 - Step 8|
|Variation #3 - Step 9|
The Finished Insert Unfolded
|Variation #3 - The Finished Insert Folded|