AIO and AI2 Cloth Diaper Sewing

Sewing AIOs and AI2 Cloth Diapers

What is an AIO or All-in-One cloth diaper? An AIO is the cloth diaper that functions the most like a disposable. It is a one piece diapering system and is extremely simple to use. It is a type of diaper that functions completely on its own without the need for extra accessories. It does not require separate soaker material to absorb or a separate diaper cover to contain leaks. All of the features are neatly packaged into one diaper. Many parents find this type of diaper to be the height of convenience since all they need is in one place and traveling requires less space.

AIOs have waterproof outer shells so you will need a waterproof fabric for the outer layer, such as PUL, Windpro, 200 or 300 wt. polar fleece, Procare, Nylon Ripstop, Ultrex, or perhaps even wool. Popular inner layers for AIOs are suedecloth, microfleece, sherpa, cotton fleece, stretch knit terry, cotton knits, hemp, velour, and flannel.

The soaker that absorbs the moisture that diapers are created to collect can be internal (hidden with the body of the diaper) making a true AIO or it can be external (snap-in or lay-in) making an AI2. Popular soaker pad materials are hemp, burley knit terry, sherpa, french terry, flannel and other absorbent materials.

**The diaper shown below is a true AIO with a hidden soaker. To make this diaper an AI2 simply eliminate the hidden soaker layer and sew the diaper as usual, then and add a lay-in trifold soaker or a serged soaker pad.**

Tools you'll need to make an AIO or AI2 diaper:

Scissors and/or rotary cutter, a cutting mat, pins, elastic, hook and loop or snap closures, a sewing machine and/or serger, and fabric.


This picture shows the outer PUL print layer and an inner layer of Sherpa. The PUL layer is a bit wider then the other layers to help with leakage.	This is the hidden layer of flannel with the soaker pad attached (3 layers of burley knit terry). This layer goes between the outer and inner layers.	To put the diaper together for sewing, put the PUL layer down first, with the "right side" facing up. The Sherpa layer goes on top of the PUL with the "right side" facing down. The "right sides" are facing each other.

Put the hidden layer on top of your other two layers.	Pin the diaper all the way around. We prefer to use the flat flower head pins.	Sew around the diaper using a straight stitch. Usually you will stitch about 1/4 to 1/2 half inch away from the edge of the diaper. You can also use a serger. Leave a 3-5 inch section open at one end.

Stitch down the elastic (on the PUL side) at the leg and back areas, using a 3 step zig-zag. We prefer Lastin.	Once elastic is applied turn the diaper inside out using the area you left "open" so that the diaper is now right sides out.	Topstitch over the opening to close it. You may want to topstitch around the whole diaper. Sew on some loop (Touchtape or Aplix) on the front on the diaper. You can also apply snaps.

Sew the hook (Touchtape or Aplix) onto the wings of the diaper. A small loop section can also be sewn on to create fold-back laundry tabs. You can also put snaps on.	Your diaper is finished! Enjoy!!