Aluminium Foil Applique Method Tutorial

In my recent post about attending Jo's Little Women Club at Traditional Pastimes, I mentioned we had a special demonstration about how to use aluminium foil to make repetitive applique pieces like leaves or circles.  I've had a few people ask me for more specific details, so here is a short tutorial with some pictures so you know what you're doing when you want to give it a try.

You will need, a pencil or pen, aluminium foil, an empty cereal box (or similar), your fabric of choice, the applique shape, general use scissors, fabric scissors, a spray bottle filled with water, and an iron and ironing surface.

Start by cutting tracing and cutting the applique shape, without seam allowances, out of the light-weight cardboard box.  Depending on how many of your shape you require, you may need to cut more than one template.  Then, holding the template in place on your fabric with your thumb and forefinger, cut the fabric 1/4" larger than the template.  Do the same thing with the aluminium foil.

You now have 1 template piece the exact size of the applique, 1 fabric piece 1/4" larger than the template, and 1 foil piece 1/4" larger than the template.  At this time you may wish to punch a hole in the middle of the cardboard template so it is easier to remove at the end.

Prepare the fabric for the foil method by spraying it with a mist of water.  It should be damp, but not soaking wet.  The water creates a little steam oven inside the foil and evaporates with the heat of the iron leaving a semi-permanent fold at the edge of your applique.  Holding the foil in your hand, place the fabric piece, right side down, on top of the foil.

Then, while holding the layered foil/fabric pieces, place the cardboard template in the center.

Carefully holding all three layers, gently fold the layered foil/fabric around the template in small sections.  Pinch the edges well as you go to hug the template firmly.  Use your finger pads to pinch, not your nails.

Now that your foil applique piece is prepared, put it on the ironing surface, folded side down and rest your iron on top, completely covering the piece, with the steam turned off.  Leave it there and count to 6 or 10, or prepare your next piece by layering the foil and pinching the seam allowance down.

Remember, when you pick up the iron, the piece will be HOT, don't use your finger to move it out of the way!  After it has cooled enough to touch it, gently remove the foil, then pop the cardboard template out of the center.  Press again to set the applique edges, and you're done!

Keep in mind that circles may not be prefect and might require a little needle poke here and there to take out any small folds or points you don't want in the final piece.  If you are doing hand applique, this can be done with your needle as you work your way around the shape.  Also, if you are making a leaf shape, it is advisable to leave a small "wing" sticking out in the direction you stitch at the points of the leaf rather than try and tuck it under at this time (if you are pinching to the left - counterclockwise - the wing will stick out to the left of the point).  Having the wing sticking out makes it easier to stitch a sharper point at the end of the leaf beacuse it gives you a small piece to tuck under at the correct angle.

Also, if you have Templar, the heat safe plastic for applique, you can cut your shape with that instead of cardboard.  Another idea is to use Karen Kay Buckley's pre-made circle templates if you are preparing circles for your project.

Hope this helps with the process!  Happy applique all!
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