Sew Custom-Fit Underwear for Everyone
Finding underwear that fits well is an ongoing challenge for everyone. Store-bought options rarely fit properly - wrong rise, uncomfortable elastic, or generic sizing that doesn't account for individual bodies. When you sew underwear, you create perfectly fitting pieces in soft fabrics, customize rise and coverage for comfort, choose fun prints everyone will love, and make complete underwear wardrobes at a fraction of store-bought costs. From everyday basics to athletic styles, comfortable sleep underwear to special fabrics for sensitive skin, sew underwear the whole family will actually want to wear.
Shop Underwear Patterns by Category
Women's underwear: Panties in various styles - bikini, hipster, brief, thong - plus bralettes and comfortable basics.
Men's underwear: Briefs, boxer briefs, and boxers designed for men's comfort and fit preferences.
Girls' underwear: Comfortable panties in fun prints - perfect for growing bodies and building underwear wardrobes.
Boys' underwear: Briefs and boxer briefs in durable fabrics - practical basics for active boys.
Perfect Beginner Projects
Underwear makes excellent beginner projects once comfortable with basic sewing. Why underwear is beginner-friendly: Very quick to sew (often 20-30 minutes per pair once you get the hang of it), uses tiny amounts of fabric - perfect for scraps, simple construction with minimal pattern pieces, immediate gratification with wearable results, and mistakes happen in private - no one sees imperfect underwear! Skills learned: Working with knit fabrics, applying elastic to curves, serging seams, and these skills transfer to other garment sewing. Small investment: Try sewing underwear with minimal fabric investment. If you love it, make dozens. If not, you've only spent a few dollars learning. Many sewists find underwear addictive - once you make pieces that fit perfectly, you'll want to make complete wardrobes in different colors and prints. Our beginner patterns include underwear options designed for new sewists.
Understanding Underwear Fit
Rise is critical: The most important measurement for all underwear - distance from waist to crotch. Too short pulls and is uncomfortable, too long bags and looks sloppy. Adjust rise at marked lines on patterns for individual torso lengths. Coverage preferences: Different people prefer different coverage levels. Some want full coverage, others prefer minimal. Make what each person finds comfortable. Leg openings: Should be comfortable without digging in or gaping. Elastic provides security without restriction. Waistband comfort: Elastic should stay in place without being tight or rolling. Width and tension matter for all-day comfort. Individual bodies: Every body is different - torso lengths, hip shapes, thigh proportions all vary. Sewing allows customization for perfect fit impossible with mass-produced underwear.
Best Fabrics for Underwear
Cotton jersey: Most popular choice - soft, breathable, comfortable, and affordable. Perfect for everyday underwear for everyone. Cotton-spandex blends add stretch and recovery for better fit. Modal or bamboo jersey: Extremely soft and gentle on skin - naturally moisture-wicking and hypoallergenic. Luxury feel for everyday wear. More expensive but worth it for sensitive skin. Microfiber: Smooth and thin - works well under fitted clothing. Quick-drying and durable. Athletic moisture-wicking fabrics: For active people or athletes - keeps comfortable during sports and activity. Cotton rib knit: Nice stretch and recovery - creates fitted underwear that holds shape through washing. Lining fabrics: Cotton jersey or cotton interlock for crotch lining - 100% cotton recommended for health and comfort. Fabric considerations: Always prewash fabrics before cutting - underwear gets washed frequently. Choose soft fabrics without scratchy texture. Look for good recovery so fabric returns to shape after stretching. Fun prints in favorite colors or patterns make underwear people want to wear. You only need small amounts - 1/4 to 1/2 yard makes multiple pairs.
Essential Elastic and Notions
Fold-over elastic (FOE): Most common elastic for underwear - folds over edges to create soft, finished waistbands and leg openings. Available in 5/8" or 3/4" width and endless colors. Stretches with fabric and lies flat against skin. Picot elastic: Decorative elastic with pretty scalloped edge - adds feminine detail to women's and girls' underwear. Plush elastic: Soft, wide elastic (usually 1") that's very comfortable for waistbands - no-roll construction. Gentle against skin. Regular elastic: Standard elastic can be used in casings if preferred over FOE method. Both methods work well. Thread: Use polyester thread for durability and stretch through frequent washing. Quality thread matters for garments washed constantly. Buying elastic: Purchase in bulk spools for best value - you'll use it quickly once you start making underwear for the family. Match colors to fabrics or choose neutrals that work with everything.
Applying Fold-Over Elastic
FOE creates professional-looking underwear edges. How to apply: Stretch the elastic while sewing (fabric stays relaxed), fold it over the fabric edge, and stitch down the center. The elastic contracts when released, creating a neat, comfortable edge. Getting even tension: This takes practice - stretch elastic consistently as you sew around curves. Too much stretch creates tight, uncomfortable edges. Too little creates wavy, loose edges that don't hold shape. Practice on scraps until comfortable with the technique. Curves are tricky: Leg openings have curves - practice stretching elastic evenly around curves. This is more challenging than straight edges but becomes natural with practice. Alternative - elastic casing: If FOE seems intimidating, create casings for regular elastic instead. Both methods work - FOE is faster and sleeker, casings are more forgiving for beginners. Color options: Match FOE to fabric or choose neutrals that work with multiple fabrics for efficiency.
Building Family Underwear Wardrobes
Per person needs: 7-10 pairs for comfortable weekly rotation - ensures always having clean underwear while others are in wash. Variety within wardrobe: Mix of basic neutral colors for everyday with fun prints for interest. Different styles for different activities - athletic underwear for sports, comfortable basics for daily wear. Family approach: Making underwear for entire family is cost-effective - buy fabric in bulk, set up machine once and sew multiple pairs efficiently. Assembly-line production: Cut all pieces for multiple pairs at once. Then sew all waistbands, all leg openings, all crotch seams - efficient way to produce many pairs quickly. Fitting each person: Make one test pair per person to perfect fit. Once fitted, replicate that pattern repeatedly with confidence. Cost savings multiply: The more pairs you make, the more dramatic the cost savings. Complete family underwear wardrobes for less than buying a few store packages per person.
Athletic and Performance Underwear
Moisture-wicking fabrics: Essential for active people - keeps comfortable during sports and workouts. Quick-dry fabrics don't stay soggy with sweat. Support considerations: Athletic underwear needs to provide support during movement while allowing full range of motion. Flat seams: Minimize chafing during extended activity - important for runners, cyclists, and athletes. Compression options: Some athletic underwear provides light compression for support during activity. Who needs athletic underwear: Anyone who exercises regularly, plays sports, or leads very active lifestyle benefits from specialized athletic underwear. Multiple pairs essential: Active people need several pairs of athletic underwear for weekly workout schedules.
Underwear for Sensitive Skin
Fabric choices matter: Soft, natural fibers work best for sensitive skin. Modal, bamboo, and quality cotton jersey are gentle options. Avoiding irritation: Use flat seams or French seams that don't create bulk against skin. Choose soft elastic that doesn't dig in. Use 100% cotton for crotch lining regardless of main fabric. Chemical sensitivities: Some people react to dyes or fabric treatments. Choose organic fabrics or those certified safe for sensitive skin. Pre-washing removes manufacturing chemicals. Seamless construction: Some patterns offer seamless or minimal-seam construction - reduces potential irritation points. Custom solutions: Sewing provides complete control over fabrics and construction - create underwear that works for individual sensitivities impossible to find in stores.
Kids' Underwear Considerations
Comfort is priority: Kids are sensitive to uncomfortable underwear - scratchy fabric, tight elastic, or wrong fit means they won't want to wear it. Fun prints motivate: Kids are more likely to wear underwear they helped choose. Let them pick fabrics with favorite characters, colors, or themes. Growing bodies: Kids grow quickly - make slightly larger if between sizes. Elastic waistbands adapt to some growth. Durability needs: Kids are hard on clothes including underwear - use quality construction and fabrics that survive frequent washing. Independence factors: Comfortable underwear kids can manage themselves supports independence and confidence. Multiple pairs essential: Kids need 7-10 pairs minimum - accidents happen, clothes get dirty, constant washing required.
Why Sew Underwear Instead of Buying
Store-bought underwear creates frustrations for everyone. Packages cost $15-30 for questionable quality and generic fit. Nothing fits properly - wrong rise, uncomfortable elastic, or doesn't account for individual body shapes. Sizes don't accommodate height variations, body proportions, or personal comfort preferences. Finding comfortable underwear for sensitive skin is nearly impossible. When you sew underwear, you get perfect fit customized to each person's body, exactly the rise that's comfortable for individual torso lengths, soft fabrics that feel good against skin all day, fun prints in colors everyone loves, quality construction that lasts through frequent washing, and complete family underwear wardrobes affordably. Cost savings are substantial - handmade underwear costs $1-3 per pair in materials compared to $3-6+ per pair store-bought packages. Make complete underwear wardrobes for entire family for less than buying 2-3 store packages per person. Plus handmade underwear often lasts longer with better fabrics and construction. For people with sensory sensitivities, tall/short torsos, athletic builds, or non-standard proportions, sewing provides comfortable underwear that actually fits - often the only way to get truly comfortable basics.
Tips for Sewing Underwear
Take accurate measurements for each person - waist, hips, and rise. Let everyone help choose fabrics they'll like. Use ballpoint needles for knit fabrics and change frequently. Prewash all fabrics before cutting - underwear gets washed constantly. Practice applying fold-over elastic on scraps before working on actual underwear. Test stitches on fabric scraps and adjust tension as needed. Use 100% cotton for crotch lining regardless of main fabric choice. Don't stretch fabric while sewing - only stretch elastic when applying it. Serge or zigzag seam allowances for comfort against skin. Make one test pair per person before cutting multiples - perfect fit first. Once fitted, cut multiple pairs assembly-line style for efficiency - cut 5-10 at once, then sew all waistbands, all leg openings, all crotch seams. Store elastic properly away from heat and sunlight to maintain stretch. Keep fabric scraps - you only need small amounts for underwear. Consider making matching family sets in coordinating prints for fun. For detailed underwear construction tutorials, visit our sewing blog for comprehensive guidance.
Common Questions
How long does it take to sew underwear?
Once familiar with the process, each pair takes 20-30 minutes. Your first few pairs take longer as you learn elastic application techniques. Becomes very quick with practice.
Is sewing underwear hard for beginners?
If you can sew basic knit garments, you're ready for underwear. The main new skill is applying elastic - practice on scraps first. Very manageable with patience and practice.
How much fabric do I need?
Each pair needs 1/4 to 1/2 yard depending on size and style - perfect for using fabric scraps and remnants. Very economical.
Do I need a serger to sew underwear?
No - a regular sewing machine with zigzag stitch works fine. A serger is helpful but not required.
What type of elastic should I use?
Fold-over elastic (FOE) is most popular - soft and creates professional finishes. Regular elastic in casings also works if you prefer that method. Both create comfortable underwear.
Is handmade underwear really cheaper?
Yes - materials cost $1-3 per pair compared to $3-6+ per pair store-bought packages. Plus you get perfect fit and exactly what you want. Savings multiply when making for entire family.
How do I get the right fit?
Take accurate measurements and make one test pair first. Adjust rise, leg openings, or coverage as needed. Once fitted, the pattern works repeatedly. This is the beauty of sewing underwear - fit it once, make dozens with confidence.
