A pocket diaper is a fitted diaper that has a “pocket” for the addition of an “insert.” The Body generally consists of four layers of material (PUL on the outside) in a contour design.  They will have elastic around the waist and legs to help fit to the baby.  They are fastened by either snaps or velcro.  They can come in sizes or be “One Size.” The insert is a several-layered combination of materials.  Sometimes an insert uses very absorbent material, and sometimes it is simply multiple layers of the same material used for the diaper body.

When using a pocket diaper, one is required to “stuff” the diaper before use, lifting the small end of the diaper open and adding the “insert.” Other than that, it works exactly like a disposable.  You put the baby on the diaper, pull the smaller part up and attach the wings to the smaller part with the velcro or snaps.

Pocket Diapers come in basically four sizes.  Newborn/Preemie, Size 1 (infant), Size 2 (crawler), and size 3 (toddler).  They can also come in One Size.The dimmensions of each size differ from brand-to-brand so it is hard to put  a standard size on them. Therefore, like a lot of disposables, Most diapers that come in sizes go by weight of the baby.   For a reference to what the normal weight-differences are between sizes of diapers, consult the “sizing your child” section.  (by clicking that link)

They are made from a variety of different fabrics.  Most of them have some sort of soft material for both the most-outside and most-inside layers.  This can be flannel or cotton.   Most pocket diapers use PUL as a waterproofing layer.  The laminated material is breathable without allowing moisture to escape the diaper. This layer is either Directly on the outside (the Laminated side on the inside of the diaper) or under one layer of softer material (depending on the material that had been laminated).  The insert may also contain microfiber or another material that is highly absorbent.

Sewing a Pocket diaper is relatively simple.  You sew the layers and then add the velcro, then sew the two layer together, adding the elastic as you sew these two layers together.  You must make sure to leave the end open for the insert.If you are using PUL, you have to make sure you don’t sew too much on the PUL because too many holes would defeat the purpose of it.  This makes it a little harder to make them look cute.  I chose to put another layer on the outside of the PUL so I wouldn’t have to worry about poking holes in the PUL when I embroidered.  Also when using PUL, sewing on the velcro patches can be interesting because you are going through the tough laminate and the layer of velcro backing.  Getting a sturdy needle is essential at this point.

Like sewing all fitted diapers, you also have to contend with Elastic, which, to a novice, can be a daunting task.  When I started making cloth, I’d never used Elastic before, and by the third diaper, I was sewing like an expert.  I could hand-sew elastic and machine sew the elastic though my fingers much preferred the use of my mother’s battered machine (I really need to get one of my own).

1. Cut out all your pieces
– 4 main body pieces (one PUL)
– 6-8 pieces for the Insert
– Velcro Tabs and Connection Piece
– Don’t cut the Elastic at this point, its easier to stretch if it remains one long strip
2. Sew the body pieces together two at a time.  Sew wrongside out, flip, then close the small end with an     over-stitch or a zig-zag.
3. Attach the Velcro.
– Sew Hook pieces to back-side of the body-piece without PUL making it so the hooks will face the        inside of the diaper when closed (sew it on hook-side down)
– Sew loop piece to the front-outside.
4. Sew two sides together with elastic in the middle (make sure to enclose the elastic).

INSERT: Sew all of them together wrong side out, flip and overstitch.  I chose to do these by hand because my machine wouldn’t go through all eight layers of material.