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You likely want a fitted cover so sew a cover 1-2" smaller than the pillow insert. So for a 30x30" insert generally you'd want to sew a 28x28" cover. To test the fit just pin the fabric around the cushion until it looks right then measure the fabric.

Add 1/2" (or more if your fabric frays easily) seam allowances to all seams for 29x29" square. Square corners aren't filled out by the pillow insert so round them off, either trace around a bowl before sewing or eyeball it when sewing.

Adding an invisible zipper along one edge is a good idea. You'll need to increase the seam allowance where you be add the zipper. Alternately you can overlap the fabric on the back like an envelope to insert and remove the cushion.

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Q: What size cover should you sew for an 30 X 30 pillow insert?
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