how to sew a zipper pouch
Filaine Thread,  Free Patterns,  Gift Ideas,  Machine Embroidery

How to Sew a Zipper Pouch with Dandelion Embroidery

finished zipper pouch

Sew a Zipper Pouch

+ Embellish with Dandelion Embroidery

Learn how to sew a zipper pouch that’s fully lined with a professional finish. Plus, add a machine embroidered dandelion that “blooms” when brushed. A fun tassel on a key ring that makes a special zipper pull provides a little something “extra” to this great gift idea.

sew a zipper pouch supplies

If you caught our FREE Serger Smarts webinar, this embroidery design is familiar to you! The same Dandelion design, available with purchase of our Pollen Slimline Palette, was featured on the Market Tote kit designed by Katrina Walker.



Determine the hoop size needed for the intended design. The featured design requires at least a 240×150 hoop. If needed, purchase extra width to fit the fabric in the hoop.

Follow the manufacturer’s instructions to fuse the Fuse ‘n Stitch stabilizer to the outer fabric for embroidery. Hoop the stabilized fabric, centering the desired design placement within the inner hoop ring. Place the hoop onto the machine.


Load the intended design onto the machine. If using the featured Dandelion design from the Sulky Pollen collection, follow the thread chart closely to determine when Filaine thread is used vs Rayon thread. Filaine thread requires a few machine adjustments that need to return to standard embroidery settings when switching back to Rayon. (See “Filaine Machine Settings” below.)

Embroider the design, clipping jump threads with each thread change.

dandelion embroidery on zipper pouch

Filaine Machine Settings

  • Install a size 100/16 Titanium Top Stitch needle.
  • Slow the machine speed by at least half.

slow the machine speed

  • Turn OFF the auto thread cutting option. This creates a small knot when the thread is pulled to the wrong side of the work, creating even more density for the needle to penetrate during embroidery.
  • Use Sulky bobbin thread in the bobbin (NOT Filaine!)

After embroidery is complete, remove the fabric from the hoop. Gently press from the wrong side (do NOT iron back and forth) to remove hoop markings.

Use the Filaine wire brush to fluff the Filaine areas, in this case the Dandelion fuzz, until the desired amount of fluff is achieved.

finished dandelion embroidery


Use 1/4″ seam allowances unless otherwise noted.

From the outer fabric, cut two 8″ x 11″ rectangles, centering the design as desired for the outer-front piece. Leave the stabilizer intact on the entire outer-front rectangle to act as an interfacing and add structure to the pouch.

mark rectangle, centering dandelion design


  • If using a zipper that’s longer than 11″, shorten it by placing it along the outer front rectangle to measure the needed length. Mark the location of the zipper stop.

measure zipper length needed

  • Stitch back and forth several times across the zipper teeth to create a new “stop.” Trim the zipper 1/4″ beyond the new stop. (Use the hand wheel to walk the needle across the teeth to avoid hitting them. This is NOT recommended for a metal zipper.)

how to shorten a zipper

Next, center the fusible fleece rectangles on each lining rectangle wrong side; fuse, following the manufacturer’s instructions.

fusing fleece to lining rectangles

Place one lining rectangle face up on a flat work surface. Place the zipper face up along one lining long edge (this is now the “upper edge.” Then place one outer rectangle wrong side up over the lining rectangle, sandwiching the zipper and aligning all edges and corners.

To get close to the zipper teeth without the presser foot getting in the way, install a zipper foot. Then stitch the upper edge, moving the zipper pull as needed to maintain a consistent seam allowance.

outer and lining fabric on either side of zipper

Repeat to stitch the opposite zipper-tape edge to the remaining lining and outer rectangles, making sure to match the lining and outer fabrics.

sandwiching zipper

Next, flip the rectangles so the outer and lining rectangles are both facing out.

Topstitch along both zipper edges from the outer fabric side, moving the zipper pull if needed to create a straight seam.

use zipper foot

Then, unzip the zipper partway.

front with zipper attached

Place the outer rectangles right sides together; use quilting clips or pins to secure, making sure all edges and corners align.

zipper and lining unstitched

In order to not forget, mark a centered 3″ opening along the lining lower edge for turning.

clip zipper ends

Stitch the pouch perimeter, beginning and ending the stitching at the marks.

lining and outer wrong side out


Trim the seam allowance to 1/4″, leaving the opening allowance at 1/2″. Then, clip the corners.

trim zipper pouch edges

Turn the pouch right side out through the opening. Then fold the opening seam allowances toward the wrong side; use quilt clips to secure.

cli along zipper pouch opening

Next, hand stitch the opening closed using a slipstitch or ladder stitch.

zipper pouch finishing

After stitching is complete, push the lining into the outer pouch. Finally, press gently, avoiding the embroidery with the iron.


To create the tassel, follow the instructions in our FREE Hobo Cork Bag webinar from Sallie Tomato. Here is a visual step-by-step!

Enjoy the finished bag!

open zipper pouch

Now make one featuring all six designs from the Sulky Pollen machine embroidery collection!

serger smarts Pollen slimline

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I am the Director of Content for Sulky of America. The former Editor in Chief of Sew News and Creative Machine Embroidery magazines, I hosted Sew it All TV on PBS for nine seasons. I've appeared on It's Sew Easy on PBS, DIY Network's Uncommon Threads, Hallmark's Marie Osmond Show, MacPhee Workshop and more! Come sew with me!


    • Ellen March

      Hi Sharon,
      The designs are available with purchase of the Slimline, which contains all the threads you need to stitch out the designs (including snap spools of Filaine). Right now we are unable to offer digital products on our site, but we will post the designs individually for sale as soon as possible!
      Thanks for writing and reading.

    • Ellen March

      Hi Sally,
      No. The Filaine thread is a heavy 12 wt. thread and it requires a design that has open, airy stitching. The design must be digitized for heavy or 12 wt. thread, and may be labeled “heavy,” “brushed, “thick,” “fur,” or the like. If you use a design that’s digitized for 40 wt. thread (which is pretty standard) you will have a lot of problems with needle and thread breakage, as there simply is more thread bulk than intended for the chosen design areas.