I haven't seen home-made all-in-ones myself, although I'm sure it's possible. My SIL used home-made pocket nappies with a lot of success. I don't have either the sewing skills or the inclination to use pocket ones (AIOs suit me better) so I didn't even venture there, but I know it saved her a lot of money.
My nappies are also home-made pockets, rather than all-in-ones (although I did make some fitteds and covers too for when my DS was really little). My pockets worked out at about $6-$8 each to make so it definitely is cheaper than buying quality MCN's. All-in-ones wouldn't be that much more as you would just need to sew in the absorbant layers rather than have them as separate inserts. One of the benefits of home made nappies is that you can adjust the fit to suit your child. My DS is tall with skinny hips and thighs so I have adjusted the leg shapes and elastic etc. to get a better fit on him.
I've made the Wee Weka pockets which were fab, also added snaps to the inside leg elastic to make those adjustable (it was super fiddly though!!!).
I've had heaps more success with making fitted nappies (like an all-in-one but requires a waterproof overnap) - I've made them with both snaps and velcro (velcro I think is loads easier with newborns!).
It works out loads cheaper. Considering it's about $3,000 to get one baby from birth to toilet/potty in disposables, and about $200-$300 to set myself up for my two with reusables (not including the washing costs etc) it has been a whole lot cheaper.
(PS I have a giant stash of materials that I won't get through all of, if you'd like me to send you a nappy-sized cut of PUL waterproof fabric and some suedecloth which is a stay-dry fabric that goes next to the skin, PM me and we can arrange!)
Mum to two very active boys, born October 2008 and December 2010. Getting excited about becoming a Childbirth Educator, and LOVIN being a birth support to amazing and courageous women!
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