How To Make

Puffy key fobs

Puffy Key Fobs In-the-Hoop Tutorial

A collection of finished puffy key fobs with 3D letters.

What Can You Do With a Key Fob?

Key fobs are versatile little projects! Use them as dangly things to hang on purses, zippers, or luggage. You can also use them as ornaments, banners, cord wraps, or for labeling things. The point is, a key fob can have many uses. Some can just be pretty and remind us to smile.

Materials Needed

For this project, you will need a main material like leather or vinyl, puff foam, and a stabilizer.

  • Main Fabric: Two pieces of a non-fraying fabric, such as medium or light-weight vinyl, genuine leather, or faux leather. Please do not use heat-press or adhesive-backed vinyl. Marine or upholstery vinyl, which typically has a plastic layer over a knit backing, works well.

An assortment of colorful faux leather or vinyl pieces.

  • Stabilizer: Medium-weight tear-away stabilizer.
  • Puff Foam: For example, GUNOLD Puffy Vegan PE10.

A package of GUNOLD Puffy Vegan PE10 embroidery foam.

A sheet of white puff foam.

Stitch Sequence

The color chart and design file for the puffy key fob.

  1. Position dieline seam
  2. Puffy foam perforation/punching seam
  3. Letter outline
  4. The entire keychain design outline

Embroidering Instructions

Step 1: Stitch the Dieline

Hoop a medium-weight tear-away stabilizer.

Tear-away stabilizer secured in an embroidery hoop.

Stitch the position dieline directly onto the stabilizer.

Step 2: Add and Perforate Puff Foam

Place a sheet of puffy foam inside the hoop so that it fully covers the stitched shape.

A sheet of puff foam placed over the stitched dieline.

Stitch the next outline. The machine needle will perforate the foam during this step.

The perforation stitch sewn through the puff foam.

Step 3: Remove Excess Foam

Gently tear away the excess puffy foam from around the stitched letter.

Tearing away the excess puff foam from around the letter.

TIP: A needle with an SES (light ballpoint) tip will perforate the foam better than needles with sharp points.

The letter shape with the excess foam removed, showing the 3D effect.

TIP: A standard 75/11 needle usually produces good results. If the foam does not tear away well, you can select a 60-gauge needle with an SES tip or remove any remaining foam particles with a hot air blower.

TIP: An extremely strong 3D effect can be achieved by using two layers of Puffy foam on the base fabric. If needed, you can bond them together with a temporary adhesive spray.

A close-up of the clean, raised letter after the foam has been removed.

Step 4: Add the Front Fabric

Place a layer of your non-fraying fabric over the design. You may use tape to hold the fabric in place. Stitch the letter outline.

The main fabric (brown faux leather) placed over the puff foam and stitched.

Step 5: Add the Backing

Take the hoop out of the machine, but do not unhoop your project. The entire in-the-hoop project is done in one hooping.

The embroidery hoop removed from the machine.

Turn the hoop over to see the back side of the project.

Place your second piece of non-fraying fabric, right side up, over the stitches. Please be sure the key fob shape is fully covered with fabric.

The backing fabric placed on the back of the hoop.

You may use tape to secure the lining so it stays flat while stitching.

The backing fabric taped securely in place.

Step 6: Final Stitch and Finishing

Return the hoop to the machine and finish by stitching the key fob's entire outline.

Unhoop the project and gently tear away the excess stabilizer.

Cut out the key fob shape, leaving about a 1/8-inch border. Please do not cut too close to the seam.

Cutting out the finished key fob from the excess material.

Tip: Use sharp scissors and long strokes for a clean edge.

Step 7: Add Hardware

Now, apply your snaps and a swivel clasp or key split ring. Adding snaps is easy; just follow the instructions that come with your snap pliers and snaps. (I got a kit on Amazon that included snap pliers, snaps, an awl, and swivel clasps).

Congratulations! You are done!

The completed puffy key fob with hardware attached.

Find more key fob designs in my shop.

An example of another puffy key fob design. An example of another puffy key fob design.

An example of another puffy key fob design. An example of another puffy key fob design.

Hope you have a lot of fun!

Anna

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