Lately, I’ve received quite a few questions about my die-cutting projects, particularly the products I use, why I use them, and how I get such clean, detailed cuts with wool felt. My recent Halloween felt ornaments seemed to stir up quite a bit of curiosity, so I thought Halloween was the perfect day to gather some of those answers together in one place!
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A Little Halloween Felt Fun
There is just something about Halloween crafting that makes me smile. Maybe it’s the playful combination of pumpkins, ghosts, witches, bats, candy, and all those wonderfully spooky little details, or perhaps it’s the excuse to fill my worktable with orange, black, purple, and green. Whatever the reason, Halloween is always a merry time in my studio.
These little felt ornaments have been especially fun because each one has its own personality. I love starting with an assortment of colorful wool felt and watching tiny individual pieces come together through die cutting, layering, embellishing, gluing, and hand stitching. They are small projects, but those little details give each one so much character. Best of all, once you understand the basic tools and supplies, the possibilities for creating your own felt projects are practically endless.
Basic Supplies for Die Cutting Wool Felt: My Favorites
One of the questions I receive most often is what I use to cut my felt. While there are a plethora of manual die-cutting machines on the market, my go-to machine is my Sizzix Big Shot (the exact system shown in the photo below and linked). I pair it with thin metal cutting dies, sometimes referred to as etched dies, to create the detailed shapes you see in many of my projects. The Big Shot is well suited to cutting felt, and thin, deep etch dies can be used for detailed felt cutting.
While these dies can also be used with paper and cardstock, when I’m working with felt, the quality of the felt makes a tremendous difference. PRO TIP: Quality felt matters! For clean, crisp die-cut shapes, be sure your felt contains wool. Skip the inexpensive acrylic craft felt for die cutting. In my experience, it is nearly impossible to get those beautiful, clean edges and tiny details with acrylic felt.
No Die-Cutting Machine? No Problem!
And don’t worry if you don’t own a die-cutting machine! You can easily cut beautiful felt shapes by hand, and there are several methods that work well. Two of my favorites start with a printed or traced pattern templates.
For the first method, I print or trace the templates onto plain computer paper and use SpraynBond Pattern & Stencil Spray from Therm O Web to temporarily adhere the paper pattern to the felt. This light-tack adhesive is designed to hold patterns in place, is repositionable, and does not leave residue on felt. I then carefully cut around the pattern with a pair of sharp scissors and remove the paper when I’m finished.
My other favorite method is freezer paper. I print (yes, you can purchase it in 8.5" x 11" sheets for your printer) or trace my pattern templates onto the freezer paper, temporarily adhere the template to the felt with a warm iron, and carefully cut out each shape with sharp scissors before removing the paper. This is a wonderfully simple option for cutting felt pieces, especially when a project doesn’t require the intricate details of a metal cutting die. Whichever method you choose, a good pair of sharp scissors and quality wool or wool-blend felt make all the difference!
My Favorite Felt
If you’ve followed me for very long, you already know that Benzie Design felt is my favorite, and it is what I use exclusively for my felt projects. I love the quality, consistency, and, of course, the incredible color selection.
Benzie Design's Wool Blend Felt collection currently includes 90 colors. Their approximately 1mm-thick felt contains 20-35% merino wool with rayon, giving me a beautiful range of colors while remaining a cost-effective choice for everyday crafting and projects that require larger quantities of felt.
For those extra special projects, I reach for Benzie Design Bellwether Felt, their 100% pure merino wool felt. The Bellwether collection currently includes 72 colors, and the felt is approximately 1mm thick with a smooth, dense finish. I especially love Bellwether for heirloom pieces, special keepsakes, and projects featuring fine embroidery or detailed hand stitching. This is the more expensive choice, but worth every penny.
The color ranges in both collections make it very easy to build a palette for just about anything I can dream up. And believe me, having all those colors at my fingertips is essential when inspiration strikes!
Needles + Thread
When hand stitching wool felt, I almost always use three plies of DMC six-strand embroidery floss.
PRO TIP: Wondering which DMC floss matches your felt? Benzie Design makes it easy! Their Wool Blend Felt Swatch Chart lists the coordinating DMC embroidery floss number right alongside each felt color, and you’ll find the same helpful color-matching information on their Bellwether 100% Pure Wool Felt Swatch Chart. Coordinating DMC floss is also available with individual felt colors on their website, taking the guesswork out of finding just the right match for your project.
My needle choice depends upon the project. If the die has conveniently cut the stitching holes for me, I generally use a #24 tapestry needle. Its blunt tip works nicely with holes that are already in place.
When I’m stitching directly through felt without precut holes, I reach for a #5 embroidery needle instead. The sharper point allows me to pierce the felt exactly where I want each stitch.
These may seem like small choices, but having the right needle for the job makes my hand stitching much more enjoyable.
Yes, I Use Glue!
Now, my fellow cross stitchers may gasp at this next part...
I use glue!
Unlike my counted cross stitch, where I'm generally reaching for a needle and thread, adhesive can be incredibly useful for felt work. Sometimes a tiny piece simply needs to stay exactly where I put it, and that's when I happily reach for glue.
For adhering felt to felt, my favorite is HeatnBond Fabric Fuse Liquid Adhesive. I find it particularly helpful for small shapes and layered elements where stitching either isn't necessary or would detract from the finished appearance.
For attaching tiny embellishments, I like Ranger Glossy Accents Sequin Glue. Small beads, sequins, and other decorative bits can be tricky to position, so having the right adhesive makes those finishing touches much easier.
My Secret Helper for Hand Stitching
Another product I frequently reach for is SpraynBond Basting Adhesive Spray from Therm O Web.
This one is a little different because it creates a temporary, repositionable bond rather than permanently gluing the pieces together. Therm O Web specifically recommends it for appliqué placement and other sewing and embroidery applications; it's sewable and formulated so it won't gum up your needle.
I especially like using Basting Adhesive when I have several small felt pieces that need to remain properly positioned while I hand stitch them in place. Instead of fighting with pins or clips, shifting pieces, or trying to hold everything together with my fingers while I stitch, a light application gives the pieces enough temporary hold to stay where I want them.
And temporary really is the important word here. The stitching is doing the permanent work; the SpraynBond Basting Adhesive Spray is simply my extra set of hands while I get there.
Therm O Web recommends a light, even coating and notes that a little goes a long way; they also recommend protecting the surrounding project and work surface from overspray.
Now, Let's Meet my Halloween Crew!
Of course, talking about supplies is only half the fun. Let's take a closer look at the three Halloween ornaments that inspired so many of your questions. Each one uses the same basic techniques, but the different shapes, colors, stitches, and embellishments give them completely different personalities. They all started as basic die-cut design shapes from Benzie Design and then I added the personality.
PRO TIP: Here’s another little trick I use when making felt ornaments! Rather than stuffing them with fiberfill or sandwiching batting between two layers of felt, I prefer to use three layers of felt for the main base. Each of the Halloween ornaments I’m sharing today has a large base shape made from three layers of felt. I love the extra structure and substance this gives the finished ornament while still keeping it flat, neat, and easy to embellish.
🎃 Purrfect Pumpkin
For my Purrfect Pumpkin, I started with the Stitchable Pumpkin Deep Etch Die from Benzie Design, then had a little fun turning an ordinary pumpkin into a playful Halloween kitty! I pulled pieces from several other die sets to create the different cat features, mixing and matching shapes until my pumpkin had just the right amount of feline personality.
I wanted this Halloween collection to feel cheerful and fun, so I brought in an unexpected pop of hot pink for the inside of the ears and the tiny nose. I was also running low on orange Wool Blend Felt, which gave me the perfect opportunity to use some of my Bellwether 100% Pure Wool Felt for this ornament. And because sometimes you simply don’t have a die for the shape you envision, I freehand cut two layers of felt for the tail and one layer for the mouth. It’s a good reminder that die cutting doesn’t have to limit your creativity. Mix and match your dies, add your own hand-cut pieces, and make the project uniquely yours!
Supplies Used:
- Sizzix Big Shot Die Cutting Machine
- Base: Stitchable Pumpkin Deep Etch Die from Benzie Design
- Black Ears: Candy Corn, Stitchable Deep Etch Die (smallest triangle used for the white section)
- Pink Ears and Nose: Felt Fright Night Feline Etched Dies by Nichol Spohr for Spellbinders
- Bellwether Felt: Rooibos
- Wool Blend Felt: Black, Flamingo, Fern
- DMC Embroidery Floss: 310, 22, 603
- Black Hemp Cord (hanger)
- SpraynBond Basting Adhesive Spray
👻 Broomhilda Boo
For Broomhilda Boo, I started with the Stitchable Ghost Deep Etch Die from Benzie Design and then gave this sweet little ghost plenty of personality! I couldn’t resist bringing in another pop of hot pink, and I thought she needed a few accessories to complete her Halloween look. A witch’s broom seemed perfectly fitting, and, of course, every stylish little ghost needs a bat barrette!
This ornament was created entirely with Benzie Design Wool Blend Felt, mixing traditional Halloween colors with that playful touch of pink. I love how just a few extra die-cut details can transform a simple ghost shape into a completely unique character. She’s not particularly spooky, but she’s definitely ready for a little Halloween mischief!
Supplies Used:
- Sizzix Big Shot Die Cutting Machine
- Base: Stitchable Ghost, Deep Etch Die
- Bat and Broom: Halloween Cutting Dies (generic from Amazon, no longer available)
- Wool Blend Felt: White, Black, Flamingo
- DMC Embroidery Floss: White, 310, 603
- Black Hemp Cord (hanger)
- SpraynBond Basting Adhesive Spray
🍬 Cornelius Candy
For Cornelius Candy, I started with the Candy Corn Stitchable Deep Etch Die from Benzie Design. He was looking a little too plain for my liking, so I decided this sweet treat needed a happy face and a little extra personality!
I freehand cut the smiling mouth and used 5mm cabochons for the eyes, attaching them with Ranger Glossy Accents Sequin Glue. And, of course, I couldn’t finish him without another pop of pink! Those adorable hot pink cheeks were cut using pieces from the Stitchable Ghost Deep Etch Die from Benzie Design. I love finding unexpected ways to mix and match pieces from different die sets. Sometimes the smallest details are what transform a simple shape into a cheerful little character, and I think Cornelius is looking pretty sweet!
Supplies Used:
- Sizzix Big Shot Die Cutting Machine
- Base: Candy Corn, Stitchable Deep Etch Die
- Cheeks: Stitchable Ghost, Deep Etch Die
- 5mm Black Cabochons
- Ranger Glossy Accents Sequin Glue
- Bellwether Felt: Rooibos
- Wool Blend Felt: White, Black, Ochre, Flamingo
- DMC Embroidery Floss: White, 22, 3822
- Black Hemp Cord (hanger)
- SpraynBond Basting Adhesive Spray
More Felt Frights & Delights
And because three ornaments are never enough when you're having this much Halloween fun, I thought I would share a few more Halloween felt creations that have recently made their way across my worktable! These felt ornaments were all made using the Halloween Felt Stitch & Create Die Collection by Nichol Spohr for Spellbinders using a combination of Bellwether Felt and Wool blend Felt.
These projects gave me another excuse to play with dies, colorful wool felt, embroidery floss, and tiny embellishments, and each one offered a chance to experiment with different combinations of color and detail. That's one of my favorite things about working with felt: even when you're using the same basic supplies and techniques, changing a few colors, stitches, or embellishments can give a project an entirely different personality.
I decided these ornaments needed a special place to hang! I layered two Grapevine Wreaths, one 10" and one 12", and wrapped them together with 3/4" Bellwether Wool Felt Ribbon. I love the rustic texture of the grapevine paired with the soft wool felt. For one final sweet touch, I added a few Candy Corn Felted Shapes around the wreath. They were the perfect little finishing detail to tie everything together!
Ready to Give Die Cutting a Try?
If you've been admiring die-cut felt projects but have been a little hesitant to try them yourself, I hope today's post gives you the confidence to jump in. You don't need an enormous collection of supplies to get started! Begin with the basics, have fun experimenting, and grow your collection over time if it brings you joy. After all, the best creative tools are the ones that inspire you to keep making. Just consider yourself warned...die cutting felt can become delightfully addictive!
I also hope this answered some of the questions you've been sending my way. I truly enjoy hearing what catches your eye in the projects I share, and your questions often inspire ideas for future posts just like this one. If there is something about my die cutting, felt work, stitching, finishing, or supplies that you're still curious about, please leave me a comment. Your question just might become my next blog post!
For now, I hope your Halloween is filled with more treats than tricks, plenty of creative inspiration, and perhaps a little time at your own worktable. Whether you're stitching, sewing, crafting, handing out candy, or simply enjoying the parade of ghosts and goblins at your door, have a wonderfully creative day.
Happy Halloween, creative friends!
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