Toy Robot cut-n-sew project

Toy Robot plush, © 2011 J. Thomson, all rights reserved. I designed this easy-to-sew soft Toy Robot for Spoonflower’s “plushie pattern” contest (my first experience making a soft toy, AND my first time using Sketchup 3D software.) The challenge was to design a soft toy that would fit on one fat quarter of fabric (18″ x 21″). It was a tough challenge to get all the necessary parts and pieces of the Robot to fit, but I finally figured it out without having to reduce the size of the finished piece. When completed, this soft Toy Robot stands over 17″ tall.

Robot Soft Toy Cut-n-Sew fabric, © 2011 J. Thomson. All rights reserved.
Keep reading for the sewing instructions to make this adorable stuffed Robot. Just purchase one fat quarter of the fabric for each Robot you want to make. [Hint: If you’re making more than one, change the repeat from “centered” to “basic repeat” under layout options when you order the fabric. Then you’ll get FOUR Robots on a single yard of fabric, which is much cheaper than ordering four fat quarters. For the contest, designed MUST be “centered”.) It was designed for the quilting-weight cotton (which is the least expensive fabric Spoonflower offers), but you can print it on other fabrics as well.

Getting Started

In addition to the fabric, you’ll need a sharp needle, some red threadblue threadstraight pinssharp scissors, and Polyester Fiberfill or other stuffing material. Optional: Medium weight fusible interfacing (to stiffen the legs and feet if you’d like him to stand up on his own. You could also use bendable armature wire inside.) If you want to get fancy, you can include some tiny magnets in the Robot’s hands and feet (glue them in or enclose the magnets with stitches so they stay put.) Embellish the Robot before you sew him up by adding some embroidered details if you like.

Sew right sides together (ie, inside out), unless otherwise indicated.

1. Pre-shrink and iron the fabric before you start, to prevent bunching up later.

2. Cut out each piece around the solid color seam allowance. Be careful not to lose the small pieces!

3. Press creases into the fabric along the solid black fold lines printed in the sewing allowance. Taking the time to do this now will make construction much easier, and you’ll wind up with a better finished project.

The Head
Toy Robot Softie Cut-n-Sew fabric, © 2011 J. Thomson. All rights reserved. The head is basically a squashed cylinder shape. There are two pieces: the oval top of the head, and a long rectangle with the face on it. The face is centered on one of the flatter sides of the oval, and the seam runs down the center back opposite the face.

1. Stitch the top of the head to the rectangular face.

2. Stitch up the vertical seam at the back of the head.

3. Turn the head right side out. Leave the bottom open for now.

4. Stitch the head onto the torso.

The Torso

1. Begin at the DOT printed in the seam allowance, stitch the sides and top together, then down the torso’s long seam. Stop when you reach the SQUARE printed in the seam allowance at the bottom.

2. Turn right sides out. Fill the Toy Robot with the stuffing of your choice. (I use polyester fiberfill.) A chopstick with smooth ends is the perfect tool to help you get stuffing into all of the corners.


Toy Robot Softie Cut-n-Sew fabric, © 2011 J. Thomson. All rights reserved.

Stitch the torso together starting at the DOT and stopping at the SQUARE.



Toy Robot Softie Cut-n-Sew fabric, © 2011 J. Thomson All rights reserved.

Finished foot will resemble a box with slanted sides.

1. Begin at the DOT, stitching the sides of the foot together to form a box-like shape. Stop when you reach the SQUARE.

2. Turn right sides out. Fill with stuffing, then sew up the last seam to close the shape.

3. Repeat with the other foot.



Toy Robot Softie Cut-n-Sew fabric, © 2011 J. Thomson All rights reserved

Sew the leg into a tube, and topstitch to the foot.

1. Stitch the long sides together to form a tube.

2. Turn the tube right side out.

3. Top-stitch the bottom of each leg (the blue end) to the top of each foot, using the STARS as a guide for placement.

4. Fill each leg with stuffing.

5. Top-stitch the top of each leg (the red end) to the bottom of the torso, using the STARS as a guide for placement.

Toy Robot Softie Cut-n-Sew fabric, © 2011 J. Thomson. All rights reserved. In the revised version of this pattern, the arms and claws are attached to simplify sewing. The arm is a cone shape, round where it attaches to the torso, and flat at the claw end.

1. Stitch the sides together, beginning at the DOT and continuing all the way around the arm and claw. Stop sewing at the SQUARE.

2. Turn the arm right sides out. A chopstick is useful here again to help you turn the claw right side out. If you have difficulty with it, try clipping the seam allowance to reduce bulk. With patience, you will succeed.
Toy Robot Softie Cut-n-Sew fabric, © 2011 J. Thomson. All rights reserved. 3. Topstitch straight across the wrist, where the claw is joined to the arm.

4. Fill the arm with stuffing.

5. Topstitch the arm to the torso, at the X.

6. Repeat with the other arm.

You’re Done!

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2 Responses to Toy Robot cut-n-sew project

  1. Bo Rainier says:

    This is a fun creative project to do on a rainy day,. I like it a lot.!

  2. Jay Thomson says:

    After sewing up the prototype last night, today I revised and simplified the pattern to make it easier. I’ve updated the sewing instructions here to reflect the changes.

    1. Reduced the overall size of the pattern by 3%.
    2. Added seam allowances to pattern pieces, simplifying assembly.
    3. Added symbols to pattern pieces, showing you where to start & stop sewing.
    4. Included assembly instructions on the selvage, so you don’t have to print them from this website.
    5. Altered the design of the Robot’s Arm and Claw, to simplify assembly. Now they are one unit, instead of 3 separate pieces. Made the arm longer, and now it is cone-shaped instead of a cylinder.
    6. Deleted the background image, as the new solid-color seam allowances make it unnecessary to prevent white showing at the seams. This resulted in a smaller file size.

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