This is a simple boxy pouch to familiarize yourself with the process and some of the concepts needed to design one for your needs. There are exposed seams inside and no linings.

Supplies

Equipment:

Sewing machine, Scissors, Pins or clips, Marker or chalk pen, measuring device (ruler or tape measure)

Optional: rotary cutter (and mat) make for straighter lines and more accurate patterns.

Supplies:

Thread, Body Fabric, Zipper (longer than desired length of pouch by at least 2 inches)

Knowlege:

How to operate a sewing machine, start and stop stitches, work with allowance in patterns.

Step 1: Cut Out Materials

For this project I cut the body fabric to be 10" x 15". This will allow me to make a box that will be 5.5"x4"x4". The way to calculate this would be (Desired Length of bag)+(Height of Bag)+(1/2" for seam allowances).

For the Pull tabs, I cut them 3"x4". This allows for the folds along the long edge to make a tab that is 1" wide and 3" long.

Step 2: Sew the Tabs

Here, fold the piece in half along the long edge (to find the mid line). Bring both the sides to meet in the middle along that mid point line. Finally fold in half so that there are no exposed edges and it should be 1/4 of the original width. Once done, stick along both edges to hold it together.

Step 3: Attach Zipper

Starting with the body material, place it "right" side up on your work surface. Next lay the zipper "wrong" side up so the the two good sides are facing but along the short end of fabric (this determines the length of the case). Take care to align the edges the length of the piece, pin, then stitch.

Note: This step is easier with a zipper foot installed on your machine. However, it can be accomplished with a general purpose foot and moving the needle to the side closest to the zipper. (See the needle placement in the 2nd/3rd picture)

Once attached, turn the fabric back so all the "right" sides are facing up (Picture 4), and top stitch the zipper again (Picture 5).

Note: This provides two functions - strengthens the seam and it helps to keep the zipper FLAT across the pouch and not drop inside looking ugly and un-functional.

Step 4: Attach the Other Side to Zipper

With the project still face up, Bring the bottom edge to the far side of the zipper. This seam is still "right" sides facing each other.(Picture 1). Take care to line up the sides before pinning to have a better product (Picture 2). And stitch as we did in Step 3.

Now invert the tube we made to bring the project right side out (Picture 3) and open the zipper so we can now do the top stitch for this side (Picture 4).

Step 5: Close the Ends

Close the zipper and invert the tube once again (now inside out). Here we flatten the project so the zipper is in the precise middle and pin in place (Picture 1).

Note: if using pull tabs, fold them in half lengthwise, and insert the folded in between the zipper and the bottom of the fabric, aligning the raw edges of all. These will be captured when we sew the ends together (See Picture 5 for an example).

I prefer to start this step on the bottom end of the zipper, this gives some support for the next part.

When you get to the teeth of the zipper, take care not to run the needle into the teeth, as this can break the needle, damage the machine, and ruin the project. I like to take my foot of the pedal and advance the machine by hand for these two or three stitches.

Next, repeat this process for the "open" end of the zipper with the pull with two additional considerations:

Mark the zipper while it is closed to help with lining it up when the zipper is separated. (see the red lines on the zipper in Picture 3
MAKE SURE the zipper is opened so the pull is inside your project - otherwise when sewn, it would blocked and useless. (Picture 4)
Don't forget the pull tab if wanted to add those (picture 5).

Now cut off excess material in the zipper. (Picture 6)

Step 6: Box the Corners

In each corner, measure/mark a square that is 1/2 the desired height of your project. (Picture 1)Measure from the seam that we sewed and not the raw edge in the allowance.

Remove that material taking care at the sticking that it doesn't come undone. (Picture 2) you can go back and stitch these points or be very careful.

Now close this hole at opposing corners and along the edges. it should make one long, straight seam. (Picture 3)

Pin in place and sew. repeat for all 4 corners.

Step 7: Appreciate Your Hard Work

You're Done!!! You can invert the project using that gap we created when we pulled the zipper down. Push out the corners to create the sharp lines and points.

You have now created your first boxy pouch. With this knowledge you can understand the considerations and planning need to design custom pouch for all your needs.

Now get out there and CRAFT!.

Introduction: Basic Boxy Pouch for Beginners