How To Sew a Rectangular Casserole Cozy (free pattern)

September 28, 2025

When I first saw a casserole cozy, I wasn’t sure what the point of it was. But now that I’ve made myself one, it’s a commonly used item in my household.

A casserole cozy is ideal because:

You can take a casserole out of an oven and set it into the casserole cozy; no need to set down a hot pad.
You can bring the casserole dish, in its cozy, straight to the table, without having a pair of oven mitts hanging out on the table while you eat.
It takes up less room on the dining table because it’s basically like a hot pad that fits snugly around the casserole dish
It keeps the dish warmer, longer when on the dining room table
I also like to use it when I need to place a casserole dish into the fridge before it’s cooled. I previously placed an oven mitt under my casserole dishes (to protect my fridge shelves from the heat).
It adds some style to my table decor

This free pattern is a little different than most of the patterns out there because it uses bias tape to finish the edges.

The binding creates a professional-looking finish, which is ideal when sewing these casserole cozies to sell.

>> I’ve since created a free pattern for square casserole cozies, which you can download here

>> You can also download the free printable pattern for a pie plate cozy here

>> And a microwavable bowl cozy here

Materials

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Fabric for top and bottom (cotton or linen are ideal; no synthetic materials as they can melt/burn/catch fire)
Thermal batting
Cotton batting
Bias tape (I used 1/2″ double-fold bias tape (2″ wide when unfolded))
Thread

Tools

Sewing Machine
Walking foot (highly recommended when working with batting)
Fabric clips or pins
Scissors
Iron

*Please be advised, a cozy is NOT microwave safe unless you use 100% cotton materials for all aspects of the cozy (thread, batting, fabric, bias tape).

Sewing casserole cozies to sell

This item may need a little more explaining to sell as it’s not as commonly known as other items in the table linen family. However, once people use one, they tend to be hooked. They’re ideal to sell because:

They make a great gift – it’s a practical item that makes a great housewarming or hosting gift and it’s unlikely someone already has one.
Serving – it replaces a hot pad on the table and makes it easy to pass a hot casserole dish around the table for serving.
Upsell item – if someone is looking at a casserole hot pad, this is a good item to upsell them on.
Evergreen – it’s a product that can be sold year-round, but can be updated for each season/holiday (e.g. Christmas-themed casserole cozy).

Although you can sell these in different sizes, it may not be a popular enough item to do so. Start with the size to fit the most commonly used casserole dish (9” x 13”) and see how it sells.

If it’s a popular and profitable product for you, you might add:

>> Square casserole cozy (free Pattern)

>> Pie plate cozy (free pattern)

If you find you have several craft show shoppers or Etsy shoppers asking for different sizes, you may consider adding bigger and smaller sizes, or sizes to fit different shapes (square, pie, loaf, etc.)

How to sew a casserole cozy

Step 1 – Press fabric & cut out pattern pieces

Print your free pattern pieces and cut them out.

Iron your top and bottom fabric before cutting, to ensure you’re making accurate cuts.

There’s no need to iron your batting.

Your pattern pieces will have a “FOLD” indication along the bottom and side.

This indicates that you must fold your fabric in a way so that those two edges will line up with folds.

Alternatively, you can print the pattern pieces twice, cut them out, and flip one over to mirror the other, then tape the pattern pieces together with no overlap.

You’ll need:

1 piece of fabric for the top of your cozy
1 piece of fabric for the bottom of your cozy
1 piece of thermal batting
1 piece of cotton batting
1 piece of (1/2″ double-fold) bias tape that is approximately 57” long

Step 2 – Layer batting and top piece

Start with your thermal batting, reflective side up, then layer your cotton batting on top, followed by your top fabric (right side facing up).

Using a walking foot, stitch all layers together by sewing two diagonal lines.

Step 3 – Sew darts

Using a 1/2” seam allowance, sew your darts on all four corners of the top piece of fabric (with batting).

Trim your batting close to your stitching, on either side of the dart, but don’t cut the fabric. Repeat this to remove the batting bulk from all 4 corners.

Sew darts for your bottom piece of fabric.

Step 4 – Set top piece into bottom piece

With wrong sides together, set your top piece (fabric and batting) into your bottom piece and line up all four corners/darts.

Step 5 – Sew first fold of bias tape

Start sewing your bias tape to your cozy about 2.5″ – 3” in from the end of your bias tape. We need this fabric loose to sew the ends of the bias tape together.

It’s also helpful to make sure the start and end of your bias tape will be on a straight edge of your cozy, and not a curve.

Sew in the crease/fold of the bias tape and ensure the raw edge of the bias tape just slightly covers the raw edges of the cozy.

Step 6 – Join bias tape ends

There are many ways to join the ends of your bias tape. Use your preferred method, or please watch the video for clear instructions. Here are the steps I follow:

Step 7 – Fold bias tape to the front and press

Fold your bias tape over to the other side of the cozy and press it into place, ensuring the folded edge just slightly covers the stitching from the other side of the bias tape.

Clip your bias tape into place, ensuring it’s covering your line of stitching.