How to Sew a Felt Santa Ornament: Step-by-Step Tutorial | Spellbinders

Handmade felt ornaments add warmth, texture, and a nostalgic touch to Christmas decorating. In this detailed tutorial, you’ll learn how to die cut, stitch, assemble, and embellish a vintage-style Santa using wool felt and embroidery floss. The project can be finished with classic stitched details and holly or dressed up with beads and sparkling embellishments.

The Vintage Santa Etched Dies cut the individual felt layers and include stitching holes to help guide the assembly. Optional batting, flannel, or thin craft felt can be placed inside the ornament for extra support and dimension. Once complete, the Santa can be displayed as a Christmas tree ornament, gift topper, window decoration, or part of a festive garland.

Hello, crafting friends! It is me again, Beverly Tiemann. I’m a stitcher, cardmaker, mixed-media artist, and quilter. The brisk weather always brings on my Christmas crafting spirit, and my favorite things to handcraft are gifts and decorations for my home.

Spellbinders recently released a collection of felt winter dies designed by Nichol Spohr. The collection includes a gorgeous cardinal, a wonderful set of trees, and this old-timey Santa. Today, I’m sharing how to make the Vintage Santa in both stitched and beaded versions.

Project Snapshot

Project Details	A layered Vintage Santa decoration made from die-cut wool felt, embroidery floss, and optional beads, embellishments, and internal support layers
Skill Level	Intermediate
Approximate Time	3+ Hours
Project Type	Handmade felt ornament or holiday decoration
Techniques	Felt die cutting, backstitching, running stitch, layered assembly, appliqué, thread-tail burying, and optional beading
Occasion	Christmas and winter holiday decorating
Finished Size	Various
Featured Product	Felt Vintage Santa Etched Dies by Nichol Spohr

What You’ll Need

Spellbinders Products

• Felt Vintage Santa Etched Dies by Nichol Spohr
  
• Felt Festive Trees Etched Dies by Nichol Spohr - optional coordinating project
• Felt Winter Cardinal Etched Dies by Nichol Spohr - optional coordinating project
• Platinum SIX Die Cutting Machine with Universal Plate System
  
• Merino Wool Felt Sheets - Holiday Collection
  
• Merino Wool Felt Sheets - Kaleidoscope Collection
  
• Merino Wool Felt Sheets - Classic Pooh Collection
  
• Buttons Galore & More Cool Yule Doo Dadz Embellishments - optional
• Buttons Galore & More Black Buttons - optional

Other Supplies

• Embroidery floss
• Embroidery or Sashiko needles
• Size 24 chenille needle
• Thin beading needle - optional
• Thin beading thread - optional
• Small sharp scissors
• Fabric or liquid glue suitable for felt
• Quilting clips
• Ribbon or baker’s twine - optional
• Quilting batting, flannel, or thin craft felt - optional
• 11/0 glass seed beads - optional
• 11/0 2.2mm Antique Gold “E” beads - optional

How to Die Cut Wool Felt

Spellbinders Merino Wool Felt can be die cut in the same way as cardstock. Build the Platinum SIX die-cutting sandwich from bottom to top in the following order:

• Plate A - Platform Base
• Plate B - Platform Top
• Plate C - Cutting Plate
• Wool felt
• Etched dies with the cutting edges facing down
• Plate C - Cutting Plate

The Vintage Santa dies can fit on the Platinum SIX platform at the same time, making it possible to cut many of the pieces in a single pass. Arrange the smaller dies over felt scraps whenever possible to reduce waste.

Although the dies are designed for felt projects, they can also cut other compatible materials. Try cardstock or thin craft foam to create Santa embellishments for handmade Christmas cards, scrapbook pages, tags, and other paper crafts.

Die-Cutting Instructions for the Vintage Santa

Cut the Facial Features and Decorative Pieces

Use the following colors and quantities as a guide when cutting the felt pieces:

• Coal felt: Die cut the eyes.
• Peachy felt: Die cut one face.
• Snow felt: Die cut two hat trims and two pom-poms.
• Snow felt: Die cut one beard, one base beard, one mustache, the buttons, and the eyebrows.
• Currant felt: Die cut two hats.
• Poppy felt: Die cut one nose.
• Hunter felt: Die cut one set of five holly pieces.

Use the swirl dies to cut decorative stitching guides into the front beard piece.

If you do not want to die cut the eyes from Coal felt, small black buttons can be substituted.

Designer Tip: Save the scraps left after cutting the larger felt pieces. These remnants are useful for the eyes, buttons, nose, holly, and other small details.

Add Optional Support and Dimension

For a fuller Santa, die cut the following support pieces from quilting batting, flannel, or thin craft felt:

• One base beard
• One hat
• One hat trim
• One pom-pom

Batting creates the most dimension. Flannel adds a softer internal layer without as much bulk, while thin craft felt is slightly stiffer and works well when the ornament includes several embellishments that need support.

The stitched sample shown here uses batting inside the beard, flannel inside the hat, and thin felt inside the pom-pom and trim.

Trim the batting around the inside edge of the stitching holes. These pieces will be enclosed inside the ornament, so they do not need to be perfectly finished or stitched through.

If you prefer not to die cut the support layers, trace around the appropriate die-cut shapes and cut the batting, flannel, or craft felt by hand. Trim the pieces slightly smaller so they remain hidden inside the finished ornament.

Prepare the Felt for Stitching

Clear the Stitching Holes

Before stitching, remove any small felt circles or “chads” remaining inside the pre-cut holes. The blunt back end of a needle works well for pushing them through because it does not pierce the felt or create extra holes that could be mistaken for stitching guides.

Stitch the Decorative Beard Swirls

Cut two strands of embroidery floss approximately 36 inches long and use a backstitch to follow the swirl guides in the front beard.

Instead of knotting the floss, catch the beginning and ending thread tails under the stitches on the back. The back of the embroidered beard will be enclosed beneath another wool felt layer, helping hold the tails securely and keeping the finished project neat.

Choose a Coordinating Thread Color

Before stitching the layers together, audition several embroidery floss colors against the wool felt. A coordinating neutral can create a soft, traditional finish, while a contrasting color makes the stitching a more prominent design feature.

Quilting clips can hold the felt pieces together while you test the placement and begin stitching.

How to Make a Beaded Felt Santa

For the beaded version, cut the same basic wool felt pieces but omit the holly, buttons, and appliquéd beard swirls. Beads and other embellishments will decorate the hat and beard in place of those felt details.

The beaded sample shown does not include a batting layer. Omitting the internal support reduces bulk and can make it easier to stitch through multiple layers while attaching small beads.

Designer Tip: Be gentle when sewing wool felt. Pulling the thread too tightly can cut through or distort the felt.

Use a thin beading thread or one to two strands of regular embroidery floss for attaching beads. A thin beading needle is useful for small seed beads. For the regular embroidery, use any needle with an eye large enough to accommodate the floss. Beverly used Sashiko needles and Size 24 chenille needles for the samples.

How to Assemble the Felt Santa

Use a Running Stitch to Join the Layers

Quilting clips can help keep the felt pieces aligned as you stitch. Sew the pieces together with a running stitch and approximately one yard of two-strand embroidery floss. A length roughly equal to one extended arm is usually manageable without becoming tangled and reduces how frequently you need to start a new thread.

When the floss becomes short, bury the tail beneath the existing stitches. Begin the next length by burying its tail in the same way.

Step 1 - Decorate the Beard

Begin by decorating the front beard piece. Follow the die-cut swirl guides with embroidery floss, or add beads and embellishments if you are making the beaded variation.

Step 2 - Attach the Face

Position the Peachy face piece over the front beard and attach it with embroidery floss. Keep the face centered and check that enough of the beard remains visible around the lower edge.

Step 3 - Add the Hat Trim

Layer one hat-trim piece against the beard base and the assembled beard and face. Place the second hat-trim piece on top. Stitch through all four layers with two strands of embroidery floss.

For the beaded version, you can add a seed bead while attaching the front trim to the beard and face with one strand of floss. Next, add the back pieces and stitch through the holes again.

Alternatively, stitch all four layers together at one time with two strands of floss and a beading needle. This method is faster, but there are more loose pieces to control. Choose whichever approach feels most comfortable.

Set the completed beard and face section aside while assembling the hat.

Step 4 - Decorate and Stitch the Hat

Attach the felt holly and buttons to the front hat piece with embroidery floss. If preferred, these small decorations can be glued to the hat after Santa has been fully assembled.

Place the optional support layer between the two hat pieces. Using a straight stitch, running stitch, backstitch, or blanket stitch, sew along both sides of the hat while leaving the bottom open.

Fill every space between the stitching holes. Depending on the stitch you choose, you may need to work around the hat a second time. Complete stitching provides additional stability and gives the edge a polished appearance.

Designer Tip: To turn the Santa into an ornament or gift topper, fold a piece of ribbon or baker’s twine into a loop. Insert and secure it inside the hat approximately 1/2 to 1 inch below the pom-pom.

Step 5 - Assemble and Attach the Pom-Pom

Stitch the two pom-pom pieces together, leaving four holes open along one of the flatter sides. These openings will align with the die-cut holes at the top of the hat.

If you are adding a support or stuffing layer, make sure it is fully enclosed inside the pom-pom. It is easiest to identify the four attachment holes before you begin sewing and then stitch most of the pom-pom closed before joining it to the hat.

Continue stitching around the pom-pom as you attach it to the hat. The four attachment stitches will be visible on the back.

To conceal those stitches, you can sew the pom-pom to the front hat layer first and add the back hat piece afterward. This method creates a cleaner back but can be slightly more difficult because of the stitching guides near the narrow tip of the hat.

Step 6 - Join the Hat and Beard

Attach the completed hat and pom-pom section to the trim and beard section. If you are decorating the trim with beads, you can stitch them in place during this final assembly step.

Another option is to bead the front trim first and then attach the remaining pieces with a second row of stitching. This adds an extra step but can make the small beads easier to manage.

Step 7 - Add the Facial Features

Glue the felt mustache, nose, eyes, and eyebrows to the face and beard section. Finish the design by adding any remaining buttons, beads, or decorative embellishments.

Tips for the Best Results

• Save your felt scraps: Use the remnants from large die cuts for small facial features, holly, buttons, and other accents.
• Clear the stitching holes first: Removing all the small felt circles makes the guides easier to see and prevents skipped holes.
• Use the blunt end of a needle: This clears the holes without accidentally piercing the felt.
• Test the thread color: Place several floss colors over the felt before stitching to see which creates the best contrast.
• Avoid pulling too tightly: Firm but gentle tension keeps the stitches neat without cutting or distorting the wool felt.
• Use quilting clips: Clips keep multiple felt layers aligned without creating additional holes.
• Trim support layers: Cut batting, flannel, or craft felt slightly smaller so it remains hidden inside the ornament.
• Bury the thread tails: Catch the beginning and ending tails beneath the stitches instead of adding bulky knots.
• Plan the pom-pom attachment: Identify the four attachment holes before stitching the pom-pom closed.

Ways to Customize Your Felt Santa

• Use beads and metallic thread for a sparkling, embellished Santa.
• Choose traditional red, white, and green felt or create Santa in colors that coordinate with your holiday décor.
• Substitute small black buttons for the felt eyes.
• Add a ribbon or baker’s twine loop to create a Christmas tree ornament.
• Attach Santa to a wrapped present as a reusable gift topper.
• String several Santas together to create a festive doorway or mantel garland.
• Use batting for a soft, dimensional ornament or thin craft felt for additional stiffness.
• Cut the design from cardstock or thin foam to create Christmas card and scrapbook embellishments.
• Personalize the ornament with initials, a date, or a small name tag.

Frequently Asked Questions

Can etched dies cut wool felt?

Yes. The Vintage Santa Etched Dies are designed to cut wool felt and include holes that guide the stitching. Use the standard Platinum SIX sandwich described in this tutorial.

What can I use inside a felt ornament?

Quilting batting creates the most dimension. Flannel provides a softer, less bulky layer, while thin craft felt adds structure and support. Trim the internal pieces so they do not cover the stitching holes or extend beyond the wool felt edges.

Which stitch should I use to assemble the Santa?

A running stitch is a simple option for joining the layers. Straight stitch, backstitch, or blanket stitch can also be used around the hat. Select the stitch that gives you the desired decorative finish while filling the spaces between the pre-cut holes.

How do I keep the embroidery floss from coming undone?

Catch or bury the beginning and ending thread tails beneath the stitches on the back of the felt. Because the back is enclosed by another layer, the tails remain hidden inside the finished ornament.

Can I make the Santa without sewing?

The design is intended for stitched felt assembly, but some small decorative pieces can be attached with a felt-compatible glue. A fully glued version may have a different appearance and structure from the stitched samples shown here.

More Wool Felt Stitching Ideas from Spellbinders

• How to Make Stitched Felt Pooh Bear and Hunny Pot Ornaments
•  Step by Step Tutorial: How To Create the Felt Berry Blossom

Create a Handmade Santa for Your Christmas Décor

The Vintage Santa Etched Dies make it possible to transform colorful wool felt, embroidery floss, and a few optional embellishments into a nostalgic handmade Christmas decoration. Follow the stitching holes for easy alignment, add support layers for extra dimension, or customize the design with beads and metallic details.

In addition to decorating the Christmas tree, these Santas would make charming decorations for windows, doorways, gifts, or festive garlands. I hope you enjoy creating your own Vintage Santa ornaments with Nichol Spohr’s Felt Stitch & Create dies.

Thank you for visiting today. If you make your own felt decorations, tag me on Instagram. I would love to see what you create!

About the Designer

Beverly Tiemann is a stitcher, cardmaker, mixed-media artist, and quilter who enjoys creating handmade gifts and decorations for the home. Visit Beverly’s blog for more photos and inspiration featuring the coordinating Felt Winter Cardinal and Felt Festive Trees projects, or follow her on Instagram.