Sewn suits are perhaps the most familar style of fursuit. These often take the form of zippered jumpsuits which are sewn from synthetic fur material. The suits aremade by following a sewing pattern. This style of fursuit is what is commonly used for mascots, rental costumes, and most mass-produced costumes. It is the easiest andmost versatile form of costume.

Advantages and Disadvantages

This style of costuming has several notable advantages. First, the costumes are (relatively) quick to make; making a sewn bodysuit involves determining a pattern (possibly the hardest part, especially for first-timers and those inexperienced at sewing), cutting the fur, and then sewing the fur together without putting a piece in with the nap going the wrong way. :) Such projects get easier with practice, however. Note that, although they might be faster in assembly, I am definitely not saying that they are less artistic or less effective as costumes.

Another advantage is that such costumes are washable, presuming the fur is washable. Synthetic furs can generally be washed with a mild detergent, such as Woolite. Be sure, however, not to put fursuits into a dryer! The heat will ruin the textureof the fur.

Although sewn suits have many strong advantages, they are not the ultimate fursuit solution. Their main disadvantags is that they are not realistic (if your goal is to protray an animal or near-animal, particularly). They are designed as clothing on a human form, and this is their limitation. However, this can be largely overcome by using padded inserts. Adding shaped pieces of foam, either individual pads or an undersuit with the padding sewn to it, can help to redesign the perceived body shape. This style of sewn suit requires more work, but is perhaps one of the most effective methods of creating a character costume.

Construction

First, you must create an appropriatesewing pattern. This is usually done by adapting a pattern you already own, but if you have a good spatial mind there's no reason you can't invent one. Practice the pattern using a cheaper material such as cotton broadcloth. Through test fittings, refine the pattern until you are satisfied.

Purchase an appropriate amount of fur (no, I can't tell you how much, since it varies a lot from pattern to pattern). Stretch the fur out on a flat surface and cut pieces corresponding to the pattern; I recommend procuring a large sheet of rigid plastic as a cutting surface and lying it on your bed. Thinner (shorter) fur can be cut from the backside with an X-Acto knife. Thicker (longer) fur seems to be easier to cut with scissors. Clean the edges with your fingers, pulling away the inevitable loose bits of fluff from the cut edge.

The fur pieces must then be sewn together (duh). This creates the finished suit. If desired, paws and feet can also be sewn directly to the bodysuit. The practicality of this technique varies with the fit of the bodysuit pattern. (Remember that those elbows and knees need room to bend!) Any foam padding inserts not already made should now be finalized. The fursuit body is then complete!

Other Notes

Sewn suits are matched with many different methods of head construction. Most often, they are used with foam or fiberglass heads. They are also used with cast latex masks and prosthetics or makeup. The paws are often sewn from fur, although latex appendages are common for "monster" costumes.