Sew a Stuffed Toy (BERNINA Midi Hoop tutorial)

I have been wanting to sew a stuffed toy for a while now.The BERNINA Midi Embroidery Hoop is an absolute game-changer when embroidering, and it makes this project smooth and simple. The ergonomic twist lock is so simple to use and it opens up easily with the touch of a button.

BERNINA Midi Hoop

Sewing this stuffed penguin was very rewarding. I love how amazing the results are when you machine embroider the details. I highly recommend that you try one of these projects. The pattern instructions also have the option to complete the project without the machine embroidery, but including the embroidery definitely makes the finished toy “next level”.

Materials Needed:

Sewing Machine BERNINA 590

BERNINA Embroidery Module

BERNINA Midi Embroidery Hoop

Midi Embroidery Hoop

With the new Midi embroidery hoop, hooping has never been easier before. The ergonomic twist-lock mechanism guarantees a quick and perfect embroidery performance.

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Drop-Shaped Embroidery Foot #26

Drop-Shaped Embroidery Foot #26 ✓ The universal embroidery foot ✓ For darning fine fabrics ✓ For optimal results, use the straight-stitch plate ✓ The shape of the presser-foot sole helps create an attractive embroidery result ✓ For 5.5 mm and 9 mm machines ✓

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BERNINA Big Book of Embroidery: Page 26 discusses different types of stabilizers and their uses.

Washaway top stabilizer, Cut-Away Stabilizer

Temporary adhesive spray

Painter’s tape

Embroidery scissors

Needles

machine embroidery needle
regular machine needle
hand-sewing needle

Thread

Sewing Thread (coordinate with body fabric)
Embroidery Thread (I used black, white, blush pink)

Fabric

There are a lot of different fabric options noted in the pattern instructions. I used fleece from two cheap throw blankets (white and grey) and stretch French terry for the beak and feet (orange).

Main body, back, tail
Belly applique
Feet, beak

Poly-fill, stuffing or fabric scraps for filling the stuffed animal

Free Pattern

Download: Choly Knight Starter Pack Plush Pattern by clicking on the icons at the end of the article
Print out pattern pieces on pages 88-90 from the PDF.

Get Ready to Embroider

Here is an article for calibrating new embroidery hoops if you need to do this.

Hoop your cut-away stabilizer. I love the BERNINA Midi hoop and the quick-release twist knob.

Because I was using a thicker fleece, I decided to hoop the 9×9 front fabric by floating it on the top of the cut-away stabilizer.

TIP: I use a cardboard box for spraying to avoid overspray. I used the box from the Midi Hoop to make a shield to avoid getting overspray from the temporary adhesive onto the hoop.

Use a cardboard box to spray temporary adhesive for floating fabrics.

Use a cardboard template to protect your hoop from overspray.

Set up your machine for embroidery by changing the needle to an embroidery needle, attaching the Embroidery Foot #26 and the embroidery module, changing the needle plate to the orange plate, lowering the feed dogs and loading the embroidery weight bobbin thread.

Embroider the Stuffed Toy: Face and Belly

Load the embroidery design Penguin Body into your BERNINA.

Stitch out the first thread colour (#1), the belly applique placement stitching line.

Stitch out the placement lines for applique.

Remove the hoop. Place the belly applique fabric over the stitched line and tape it into place.

Return the hoop to the machine and stitch the applique outline in a thread that matches your belly fabric. (#2)

Remove the hoop and cut away extra fabric from the applique outline by trimming very closely to the stitching line.

Tape the water-soluble top stabilizer on top. This helps keep the stitches from sinking into fuzzy fabrics.

Finish stitching out the remainder of the embroidery design; the blush, eyes and top placement line.

Washaway embroidery topper keeps stitches from sinking into thick fleece.

Remove the Midi Embroidery Hoop from the unit and remove the fabric from the hoop. Cut away the stabilizers carefully.

Cut away excess stabilizer.

Sew the Stuffed Toy: Front Body

Remove the embroidery unit from your machine and set it up for regular sewing.

Sew the darts on the body front.

Sew the feet together with the wrong sides together. Turn the feet and lightly stuff.

TIP: Trace the feet and the stitching lines onto tracing paper or thin interfacing. Stitch through the feet tracings to make it easier to get the details when stitching.

Stitch right through the thin interfacing for accuracy.

Baste the feet onto the body front. I used a stitch length of 4.

Baste the feet into place.

Sew the Stuffed Toy: Back and Front Body

Leaving the opening for stuffing unstitched, stitch the two back pieces together.

Using the sewing machine, sew the tail pieces, turn right side out, and baste to the back body.

Then, stitch the penguin back to the front body.

Stitch body front and back together.

Stitch the flat bottom piece to the main body. This can be tricky to do. I sewed very slowly and engaged the dual feed to help feed the fabric through the machine.

Turn right side out through the opening in the middle back and stuff.

Use a ladder stitch and hand-sew the back opening closed.