Puff Foam Ornaments (In-the-Hoop)

When you download the design, you will find multiple files. Some are embroidery files, and others are dieline files marked with the letters "DL". Dielines are used to cut the fabric to the correct shape and size. Open and print each dieline file using an embroidery software. If you do not have an embroidery software, take a look at our helpful video on using dielines.

We also recommend Wilcom's Hatch software which comes in different levels depending on what you'd like to use the software for. Hatch Organizer works well to view your designs, print dielines and templates, change design colors, and create basic design layouts. (This is an affiliate link. We may earn commission on purchases made with this link.)

First, spray the back side of the printed "front piece" dieline with temporary spray adhesive, and smooth it onto the right side of the felt.

Cut the "front piece" dieline shape out the felt. Then remove the paper dieline.

Repeat to cut out the "back piece" as well.

Once all the fabric pieces are cut to the correct shapes, it's time to embroider the design.

Hoop a piece of tear-away stabilizer. Madeira E-Zee 1.5 oz. or Floriani Tearaway Medium are good choices. Those brands are more fibrous, less like paper, and will tear more cleanly.

Attach the hoop onto the machine, and load the embroidery file (not the dieline files).

Use a 75/11 sharp sewing needle instead of an embroidery needle. The sharp sewing needle has a finer point, and it will make smaller perforations in the stabilizer.

Embroidery the design. The first thing to embroider will be a dieline (or outline stitch). This marks the area on the stabilizer where the fabric piece will be placed.

After the dieline has sewn, remove the hoop from the machine, but do not unhoop the stabilizer.

Spray the wrong side of the "front piece" with temporary spray adhesive. Place the fabric on the stabilizer inside of the sewn dieline.

Then place the hoop back onto the machine, and embroider the tackdown for the previously placed "front piece". A tackdown holds the fabric piece in place for the remainder of the design.

Follow the color change sheet and embroider the first of the inner details, but stop before the "detail (puff)" step.

Some embroidery designs are specially digitized to be used with puff foam. When using puff foam with these designs, heavy satin stitches cover the foam to create a raised, dimensional effect.

Choose a puff foam that matches, or is close to the color of the thread you will be using.

Remove the hoop from the machine, but do not unhoop design. Then place a piece of puff foam that fits within the embroidery hoop down on top of the design.

Using painter's tape, tape down the edges of the foam to prevent shifting as you embroider out the puff foam details.

Return the hoop back to the machine, embroider the "detail (puff)" step. As the design embroiders it will perforate the foam while stitching, making it easier to remove in the next step.

When the "detail (puff)" step is finished, once again remove the hoop from the machine and do not unhoop the design. Peel away the tape and remove the foam.

Before sewing the "back piece tackdown" step, turn the hoop over so the back side of the embroidery is facing up.

To add a hanger onto the ornament, cut a length of ribbon 7" long, and make it into a loop. Tape the loop into place along the top center edge of the ornament.

Then spray the back side of the "back piece" fabric with temporary spray adhesive, and smooth it inside the shape on the back of the embroidery.

As the bobbin stitching from here will be visible from both sides, wind a bobbin to match the thread color used in the top of the machine.

Place the matching bobbin into the machine and reattach the hoop to the machine and embroider out the "back piece tackdown" step.

Once the embroidery is finished, carefully tear away the excess stabilizer from the outside of the ornament.

If there are bits sticking out from the satin stitches, use tweezers to remove them.

Puff foam can also be pushed into the satin stitches with the point of a small scissors as well.

The "back piece tackdown" step will also leave an opening in the ornament. This opening is left to be able to stuff the ornament with polyester fiberfill.

Using the opening in the ornament, fill with polyester fiberfill.

When the ornament is stuffed completely, use a hand sewing needle to sew along the original tackdown line and sew the ornament closed.