Puff Underlay Keychain

Create your own puff underlay keychain with this new puff foam technique!

Supplies & Materials:

- Thread

- Non Fraying Fabric - we are using faux leather

- Scissors

- Keychain Hardware

- Awl

- Cutaway stabilizer

- Temporary spray adhesive

- Puff Foam

The designs used in this tutorial include:

- Celtic Keychain (In-the-Hoop) (Puff Foam)

Hoop a piece of cutaway stabilizer.

Embroidery hoop with white tear-away stabilizer hooped and edges extending beyond hoop frame, placed on a dark gray fabric surface.

Attach the hoop onto the machine, and load the embroidery file. Begin to embroider the design. The first thing to embroider will be a dieline (or outline stitch.) This marks the area on the stabilizer where the puff foam will be placed.

Close-up of an embroidery machine stitching a blue outline of an irregular shape on white fabric hooped in a beige embroidery frame.

After the dieline has sewn, remove the hoop from the machine, but do not unhoop the stabilizer. Cut a piece of embroidery puff foam that is slightly larger than the stitched dieline.If you want a more dramatic puff, you can stack two pieces together.

Embroidery hoop clamped with white stabilizer fabric inside, outlined triangular shape stitched in black thread, small square white foam piece on dark gray textured surface.

Spray a piece of embroidery puff foam with temporary spray adhesive and smooth it onto your cutaway stabilizer over the dieline. If you do not have embroidery puff foam, one or two pieces of craft foam will also suffice.

Hand holding and lifting a layer of white puff underlay fabric from embroidery hoop with stitched black outline of a heart shape on white stabilizer.

Place the hoop back onto the machine put the hoop back on the machine embroider the puff perforation line. This will make it easy to tear away the excess foam around the puffed area.

Close-up of an embroidery machine stitching a triangular outline onto a layered fabric piece held in an embroidery hoop on a white surface.

Remove the hoop from the machine and carefully remove the puff foam outside of the die line. If there are small areas that did not tear completely cleanly, you can use small scissors or tweezer to help remove those parts.

Hand holding peeled white puff underlay material over black embroidered outline of a heart shape on white stabilizer fabric, all secured in embroidery hoop.

Place the hoop back on the machine and stitch the top fabric dieline. Depending on the design it may or may not be the same as the puff foam dieline.

Close-up of embroidery machine stitching layered fabric pieces with green and yellow thread on white fabric inside a hoop. Layers create a raised shape.

Remove the hoop from the machine and cut a piece of your main fabric that is slightly larger than the stitch dieline. Spray it with temporary spray adhesive and smooth it onto the hooped stabilizer and puff foam piece.

Hand pulling back a black fabric piece from a white textured backing inside an embroidery hoop with a partially stitched outline in green and gold thread on white stabilizer.

Place the hoop back on machine and embroider the top piece tackdown.

Close-up of a sewing machine stitching an irregular heart shape outline on a dark teal square piece of textured synthetic leather fabric, framed by a white embroidery hoop.

Once the front fabric piece is tacked down into place, embroider all the inner details. Make sure to stop before sewing the "back piece tackdown" step.

Close-up of teal leather piece under sewing machine needle, embroidered with a gold Celtic knot design outlined by dense teal stitching on white surface.

Remove the hoop from the machine. Cut a piece of the back fabric that is slightly larger than the front piece dieline. Spray with temporary spray adhesive and smooth it onto the back of the hoop.