Embroidery Library

Puff Foam Ornaments
(In-the-Hoop)

Free project instructions for creating puff foam ornaments, in-the-hoop.

Free project instructions for creating puff foam ornaments, in-the-hoop.


Elevate your Christmas decor with in-the-hoop ornaments featuring puff foam accents! Adding puff foam during stitching gives certain areas of the embroidery a raised, three-dimensional effect. These designs are simple to stitch, and truly stunning -- we'll show you how to stitch your own!


Project Needs & Notes:

- 1/2 yard felt
- Scissors
- Masking tape or painter's tape
- Temporary spray adhesive (such as Gunold KK100)
- Tear-away stabilizer
- 1/8" wide ribbon for hanger
- 2-3mm puff foam
- Embroidery thread
- Polyester fiberfill
- Needle and thread for hand sewing

Designs featured in this tutorial include:
- X14923, Filigree Ornaments - Star (Puff Foam) (In-the-Hoop)

Free project instructions for creating puff foam ornaments, in-the-hoop.

When you download the In-the-hoop puff foam ornament design, you will find multiple files. Some are the embroidery files, and the 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 embroidery software. If you do not have embroidery software, Wilcom TrueSizer is a free program to use.

Print enough copies of the dielines so you can cut out each shape.

Free project instructions for creating puff foam ornaments, in-the-hoop.

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.

Free project instructions for creating puff foam ornaments, in-the-hoop.

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


Free project instructions for creating puff foam ornaments, in-the-hoop.

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

Free project instructions for creating puff foam ornaments, in-the-hoop.

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.

Free project instructions for creating puff foam ornaments, in-the-hoop.

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.

Free project instructions for creating puff foam ornaments, in-the-hoop.

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.

Free project instructions for creating puff foam ornaments, in-the-hoop.

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.

Free project instructions for creating puff foam ornaments, in-the-hoop.

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

Free project instructions for creating puff foam ornaments, in-the-hoop.

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.

Free project instructions for creating puff foam ornaments, in-the-hoop.

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

Free project instructions for creating puff foam ornaments, in-the-hoop.

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.

Free project instructions for creating puff foam ornaments, in-the-hoop.

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.

Free project instructions for creating puff foam ornaments, in-the-hoop.

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.

Free project instructions for creating puff foam ornaments, in-the-hoop.

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.

Free project instructions for creating puff foam ornaments, in-the-hoop.

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.

Free project instructions for creating puff foam ornaments, in-the-hoop.

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.

Free project instructions for creating puff foam ornaments, in-the-hoop.

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

Free project instructions for creating puff foam ornaments, in-the-hoop.

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

Free project instructions for creating puff foam ornaments, in-the-hoop.

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

Free project instructions for creating puff foam ornaments, in-the-hoop.

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

Free project instructions for creating puff foam ornaments, in-the-hoop.

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.

Free project instructions for creating puff foam ornaments, in-the-hoop.

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

Free project instructions for creating puff foam ornaments, in-the-hoop.

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

Puff Foam Ornaments (In-the-Hoop)



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Products used in this Project: