I've been meaning to make some reusable snack bags for quite a while. The research process was long, especially for the interior. I finally decided on uncoated ripstop nylon. Then I had to choose, gusset or not gusset? What closure? I finally decided no gusset and velcro for the closure.
My first prototype was a gusset bag thinking it would be nice to have a roomy bag that would fit thicker sandwiches. It was so large it was claimed by my oldest as a toy carryall. Oops!
I shaved half an inch on all sides of my second bag and it was a much more reasonable size.
However, I quickly realized that a roomier flat bag would give me flexibility for larger sized sandwiches without having to fiddle with turning and topstitching the top edge of a lining & outer fabric.
The second set of bags is sewn flat with french seams so there are no exposed seams inside to catch crumbs. I just traced around a disposable sandwich bag and added seam allowances. Then I followed this tutorial. Voila! A full sized and half sized bag. I told Mr. Maricucu his assigned bag for work will be the one on the right and he said no thank you. Wonder why?
Next to a disposable bag for scale.
Roomy enough for a sandwich.
The half size holds a generous amount of pretzels. Once I get more sew-in velcro I will finish the others I have cut out.