Star Trek: DS9/NEM Duty Jumpsuit Analysis/Tutorial

Welcome to the Bad Wolf Costumes analysis of the Star Trek: Deep Space Nine to Nemesis-era duty jumpsuit and its corresponding sewing tutorial!

We primarily researched and analyzed the DS9/NEM jumpsuit for our sewing pattern, which is available for purchase from our Etsy shop, web site, and eBay store (see right), but we're happy to share our research and findings with you here, as well as the free sewing tutorial intended to accompany our pattern.

A free downloadable PDF version of this analysis/tutorial is available here on the Bad Wolf Costumes web site for your convenience.

This analysis/tutorial is, at present, primarily focused on the male screen-used garments for observation; we plan on updating this blog with the relevant examples of female uniforms once our female jumpsuit pattern is released. The male and female DS9/NEM jumpsuits were more or less identical in construction except for the obvious size differences and the inevitable outliers (such as the spandex versions worn by Jadzia, Ezri, Crusher, and Troi). 

Lastly, we'd like to extend a special thank-you to Michael Cowart for his consultation and inspiration, the Starfleet 1701st for being a wealth of information and its board members for contributing, and TrekCore for its enormous library of HD screencaps.


  1. I've got a question.
    I'm currently working on the yoke (A muslin at this time). In page 97, you mention:

    "Once quilted, serge the entire quilted assembly."

    I'm new at serging (just got a serger a month or so ago). Do you mean to keep the cutter on the serger? What settings do you use for your serging? what type of stitch?

  2. I like to serge with the blade, but trimming off as little as possible; this makes the edges nice and flush (if they aren't already).

    Any overlock stitch no wider than your seam allowance (3/8" in this case) is fine. I have my serger set to a 1/4" stitch width.