Hi friends, it's Natalie from Sew Hungry Hippie! Today we're talking about one of my favorite money-saving tricks in the sewing room: Franken-foam.
If you've never heard that term, here's the deal. You know that pile of foam scraps you can't bear to throw away? (Same.) Franken-foam is simply joining those scraps together until you have a piece big enough to use in your bag. I've done it with foam, quilt batting, Woven Interfacing, and I've even done it with Decovil Light. Same idea every time.
Only have a minute? Here is my very fast instagram reel tutorial.
Want all the methods outlined and shown in regular time? Watch my Frankenfoam YouTube tutorial here.
What You'll Need
- Foam scraps
- Acrylic ruler and rotary cutter
- Cutting mat
- Sewing machine with a wide zigzag stitch (for Method 1)
- Fusible batting tape (for Method 2)
- An iron. I use my Oliso Mini because it heats up so fast
- Woven Fusible Interfacing for a smooth finish
- Your exterior fabric
- Good thread. I use Gütermann, and I recommend a poly blend because it tends to be stronger
Step 1: Get a Perfect Fit (Do This for Every Method)
So your scraps have wonky edges that don't meet. No problem. This is the secret to a seam you can't see.
- Overlap the two scraps where you want them to join. Just layer one right over the other.
- Lay your acrylic ruler on top across the overlap so you get a nice straight line.
- Cut through both layers at once with your rotary cutter.
- Put your blade away! Safety first, always.
- Remove the two little trimmed bits. Now your edges match exactly, like puzzle pieces.
Don't worry about the length or height of your piece yet. We'll trim to your pattern piece later.
Method 1: The Zigzag Stitch
No batting tape on hand? You can absolutely just head to your machine.
My settings: a big, open zigzag. Width at 4.7 and stitch length (how close the threads sit together) at 1.7. You do NOT want a tight satin stitch here. That gives you puckers and bumps.
- Test your needle width first. Make sure you have the right foot on for a wide zigzag. You do not want to hit your foot, break a needle and send it flying. Safety first.
- Butt your two edges together under the needle so the zigzag lands on each side of the gap.
- Sew slowly, gently guiding with your hands. You're not pushing the foam forward. You're just nudging the two edges together as you go.
Don't freak out if your first try looks funky. My first sample had some looping and it wasn't perfect. I was pushing the pieces together too hard. Your machine may also need a tension tweak (mine didn't, but yours might). Every machine stitches a little differently on foam. My Bernina looks different from my other machine, front and back. Play with it. You're not doing anything wrong.
Method 2: Fusible Batting Tape (My Favorite)
Sometimes, depending on the machine, I just don't feel confident I can keep those edges together while sewing. That's when I grab fusible batting tape.
- Make your perfect cut (Step 1) and butt the edges together on your pressing surface.
- Cut a strip of tape to cover the seam. It doesn't need to be super long. Trim it so none of the bumpy adhesive hangs off onto your pressing mat. (My wool mat is too expensive to be messing up.)
- Press with a hot iron. I use mine on Hell's Gate, full blast, high heat. That's how I roll.
- Check the seam. If the edges didn't stay together, lift, push them back together, and try re-fusing. Sometimes that works, sometimes you'll need a fresh piece of tape.
- Going for a masterpiece? If it's an expensive bag with really nice vinyl, I tape the back side too, for extra security.
Once the tape is on, you don't need to zigzag. It really will hold. If you want to zigzag over it anyway, you're not wrong. Whatever floats your boat!
What about Wonder-Under tape? It has adhesive on both sides, so you'd have to fuse everything all at once. I find batting tape easier because you can get the seam really tight first and then fuse. Wonder-Under is a bit pricier too, I think. But try it and let us know!
The Finishing Step I Never Skip: Woven Fusible Interfacing
Here's what I do every time, and it's what makes Franken-foam look totally professional.
- Cut your joined foam to your bag pattern piece.
- Cut a piece of woven fusible big enough to cover the whole thing.
- Place the bumpy adhesive side down on the foam, on the side that will face outward, and fuse. Now you have a nice smooth surface and two layers of adhesive holding that seam. It will last and last. It's not coming apart.
- Lay your exterior fabric on top, right on the woven fusible and smooth it down and baste around the edge. You're sewing through foam, woven fusible, tape, and fabric.
You can fuse WF to the other side too, but I usually don't. One layer on the outward side is plenty.
Look how smooth that is! You can't see the join at all. Just a really classy result.
Your Questions, Answered
Can I join lots of tiny pieces into one big piece? Yes! But use your judgment. For a big bag like the Santorini Tote, I wouldn't piece a whole large panel out of tiny scraps. I never want weak spots in a bag that's getting slung over your shoulder with big straps. For small projects like a zipper pouch, an Easy Zipper Case or an essential oils case? Go for it.
How do I get a fold wrinkle out of foam? Steam the heck out of it. Put water in your iron, crank it to high, and hover just above the foam. No steam iron? Spritz it with a water bottle and press. This foam is polyester with other fibers in it, so it takes steam and pressing really well.
My zigzag is looping or skipping. Help! Try a different thread. I use Gütermann because it works great in my machine. If you're using all-cotton or a really fine thread, try a poly blend. Grab your big coupon, head to the big box store, buy a few kinds and see what your machine likes.
Should I really keep all my scraps? I keep a big bag of foam scraps and never throw them away. It's too expensive! If a piece is big enough for a zipper pouch, I save it whole. Weird leftovers get Franken-foamed.
But here's my caveat: if stuff in your sewing room is weighing you down, donate it so you feel happy in your space. Elementary and middle schools are often looking for fabric and interfacing donations. It's worth a phone call. If it doesn't bring you joy, bye! No judgment!
Go Make Some Franken-foam!
Play around and experiment. And remember: if something fails, it's not you. It's just a method and a skill you're working on and honing. There's nothing wrong with you, so don't feel that way.
Show me your Franken-foam creations in the Sew Hungry Hippie Facebook Makers Group.
Happy sewing!
Natalie, Sew Hungry Hippie
Then turn it into a pouch! The piece below is going to be just that!
Below is Deep Space Soft Vinyl.
