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Definitely, the making of molds to get a perfect headrest cover is of great importance.
Some headrests are bulky and rounded difficult to mold as if they were flat surfaces.
As we can see, I first have gotten the mold directly from the headrest foam base using cardstock paper. I only used a half side considering the othe half is the same. Then this distorted mold is transferred to a new cardstock paper to get a 'flat mold' that would be replicated on materials such as vinyl or leather.
This academic technique is taught in our basic courses and can be applied to different upholstery projects.
'Flat felled seams or oversewing' is an ornamental stitch on top view close to junction sewing lines. It helps to flatten the seams and make the fitting process of the cover onto the foam base much easier.
Oversewing on car headrests should be done on post or cylinder sewing machines. It can also be done with flat bed sewing machines with some difficulty though.
Spring loaded guide presser feet make our 'oversewing' much better.
Regularly, to ease the sewing process, pieces with straight edges should be on top of pieces with rounded edges. The small round piece should remain flat on the sewing machine table. The other piece with straight edge is manipulated and sewn down all around the rounded piece edge.
I hope you find this video useful!
Cesar