The size of the batting you choose to buy will depend on how large you want your blanket to be. Prepackaged batting usually comes in standard widths of 45 and/or 60 inches. However, if you buy the batting custom cut, you can get it in any size you wish. You can choose either cotton or polyester batting. Cotton is more soft to the touch, while polyester is stiffer. Often cotton batting comes pre-shrunk as well which is a bonus. You will also need to choose whether your batting will be high or low-loft quality. High-loft quality is a thicker batting. Low-loft quality is a thinner batting that helps to lay your blanket out flat. Try to find batting which is in sheet form rather than loose. Sheets of batting are much easier to handle, cut, and sew.
Because flannel comes in so many different colors you can, in general, only buy it prepackaged. If you are making a custom-sized blanket, buy a prepackaged flannel which is slightly larger than the size of your blanket. You can then cut it down to the proper size later on. The labels on the prepackaged flannel will also detail the thickness, which varies depending on the brand.
If you buy plush fabric off of the bolt, make sure that you get the same dimensions as both the flannel and batting. If you buy it prepackaged, make sure that it is slightly larger than the flannel and batting so that you can cut it down to the proper size later on. Since this is the fabric which will touch your skin as you lay underneath, you will need to check whether the material bothers your skin. You should also check the added dyes in the fabric and whether or not you have an allergy to it.
Try to get a color which matches the flannel and plush fabric. If you wish to see the stitch design, make sure to purchase a high contrast color of thread and embroidery floss. You will also need to buy a needle with a large eye so that the 6-count embroidery floss can easily slide through.
It they were cut directly off of the bolt, and therefore cut, put them in separate mesh laundry bags. You can then wash them with cold water and safe fabric detergent. You do not have to wash the batting if it is already preshrunk. If it isn’t preshrunk, gently hand wash the batting with cool water, a soft washcloth, and a touch of fabric detergent. Run it under cool water when you are done to get the fabric detergent out. The flannel and plush fabric can be dried in your home dryer on low heat. Batting that has been washed should hang dry.
Pin the pieces of fabric together so that they do not slide as you cut them. You can either cut them with a pair of scissors or a rotary blade. If you use a rotary blade, make sure you do the cutting on a safe surface. Cut the fabric in sections. You can use a ruler as you go down to make sure that the dimensions of your fabric stay the same down. Use a small, light pencil mark when you are marking where you want to cut.
Once you have them in the correct order on top of one another, straighten them out. Place pins through the inner part of all three layers so that they stay straight when you begin to sew.
Use a ruler or a straight edge to keep the masking tape straight. Leave the tape on until you are sewed. You can also replace the tape with a simple light pencil line, although this may be hard to see as you are sewing.
You can create curved stitch marks at the corners, or stop your sewing machine, and reposition your material 90 degrees so that you create a sharp sewn corner. When you get close to finishing, leave a hole about 6-8 inches long, from where you stopped to where you began sewing.
Stick your needle underneath the batting, and through the top, already threaded hole in the plush fabric. Pull the thread through, while holding a finger near the edge of your fabric so that the thread does not pull through all the way. Stick your needle through the loop created by your finger. Pull the needle all the way through until the stitch is tight. Stick your needle underneath the batting, about 1/2 inch away from the previous stitch, moving downwards. Slide the needle through all three fabrics, while keeping your finger near the edge to create a loop. Stick your needle through the loop and pull tight. Repeat the previous step over and over again, until you have made your way around the blanket. If you need to add another piece of floss, simply tie a knot and begin again at the spot where you left off. Remember to leave a 6-8 inch hole between where you finally end, and where you began sewing.
After you have trimmed the excess, you can peel off the masking tape, and pull out the pins that were stuck in your blanket to hold it down.
Once you are done with the top edge, flip your blanket upside down. Turn your iron on low again, and press the edge of the flannel down. Do this around the edge of the blanket.
It is important to do this slowly so that you do not accidentally rip out any of the stitching. Once you get the bulk of it flipped inside-out, tuck your hand back into the hole and poke your finger into the corners. You can also pull from the outside to make them straight and not bunched inward.
Take your needle around the edge, and slide it into the flannel underneath. Stick your needle through the three fabrics, and up through the hole you already sewed through. As you are pulling the thread through, place your finger on the edge of the fabric so that the thread does not go all the way through. Take your needle and slide it through the loop you created with your finger. Pull the thread tight. Slide your needle underneath the flannel about a 1/2 inch down from the previous stitch. Slide your needle through all three fabrics as you hold your finger on the edge of the blanket to catch the thread. Put your needle through the loop you created with your finger, and pull your thread tight. Repeat the previous steps over and over again until you have stitched the hole together. Tie a knot in the thread when you are done.
