DIY Paw Patrol Chase Tutu & Embroidered Shirt: Complete Step-by-Step

Video reference: “Making a Paw Patrol Chase Tutu Outfit! Step-by-step tutorial!” by Kayla's Creations

A birthday outfit that twirls, sparkles, and shouts “Chase is on the case!” This guide shows you how to sew a double-ribbon tutu and embroider a matching shirt featuring a glitter 2, the Chase appliqué, and a name. It’s the complete walkthrough—clear, sequential, and kid-proof.

What you’ll learn

• How to measure, fold, and cut tulle for a toddler tutu with clean edges

• How to sew a 1-inch elastic channel and add a double satin ribbon trim

• A reliable way to thread 3/4 inch non-roll elastic without snags

• How to embroider a glitter-vinyl appliqué number, the Chase character in felt, and a name

• Quality checks and fixes that keep your tutu and shirt looking pro

Primer: What this outfit is and when to make it The project is a Paw Patrol Chase-themed tutu paired with a personalized embroidered shirt—perfect for birthdays and photo ops. You’ll cut and fold 10 yards of tulle for a size 3T tutu, sew a 1-inch waistband channel for 3/4 inch elastic, add double ribbon trim, then embroider a glitter number, Chase appliqué, and a name on a white shirt. machine embroidery

• Use this when you want a fluffy, ribbon-trimmed tutu with a polished finish.

• Expect intermediate-level sewing and basic embroidery skills.

• The method focuses on careful folding, consistent seam allowances, and clean finishes that hold up to toddler play.

Prep: Tools, materials, and workspace Materials for the tutu

• Tulle: 10 yards for a size 3T tutu (cut to 16-inch length)

• Satin ribbon: yellow, single-sided (for double ribbon trim)

• Elastic: 3/4 inch non-roll, 20 inches long for a 3T waist

• Threads: navy (channel), yellow (ribbon), white (elastic join)

Materials for the embroidered shirt

• White shirt

• Glitter embroidery vinyl for the number “2” (glitter HTV also works; heat press after)

• Felt (for Chase’s appliqué pieces: face, ears, body, hat)

• Embroidery thread in appropriate colors

Essential tools

• Acrylic sewing ruler, scissors, rotary cutter, cutting mat, clips

• Sewing machine and lighter (for heat sealing ribbon ends)

• Large safety pin and electrical tape (for threading elastic)

• Basting adhesive (to secure elastic overlap)

• Embroidery machine and small scissors for trimming appliqué

Workspace setup

• Clear a large, flat cutting area.

• Place boxes on either side (and/or below) your sewing table so the tulle slides into them instead of the floor—keeps it clean of lint and fuzz as you sew.

Quick check

• Thread/bobbin loaded to match your current task (navy for channel; yellow for ribbon; white for elastic join).

Prep checklist

• 10 yards tulle ready

• Yellow satin ribbon and lighter within reach

• 3/4 inch non-roll elastic cut to 20 inches

• Safety pin + electrical tape taped and ready

• Shirt, glitter vinyl, felt, and embroidery threads set aside for later brother sewing machine

Setup: Dial in your machine and folds Why folding matters Folding the tulle back and forth over a ruler keeps layers even and reduces waste. With the stack neat, you’ll cut a clean 16-inch length for a 3T tutu.

Machine setup for the channel

• Tension: Test on a scrap of tulle. The sweet spot used here was tension 4.

• Stitch: Straight stitch, center position.

• Stitch length/width: Set to a comfortable straight-stitch length (tested settings showed a stitch length around 2.5 worked well). Keep your seam allowance consistent at 1 inch to fit 3/4 inch elastic.

Tulle fold for double ribbon trim

• After cutting to 16 inches, unfold and refold lengthwise so the top layer sits about 1 inch higher than the bottom layer—this creates visible double layers once the ribbons are sewn on.

• Clip sections so the overhang stays consistent.

Setup checklist

• Tension tested on scrap (target 4)

• Straight stitch selected; seam allowance 1 inch

• Folded tulle with a consistent 1-inch offset for the double-ribbon effect embroidery hoops magnetic

Operation: Build the tutu step-by-step 1) Measure and cut the tulle

• Unroll and measure 10 yards.

• Fold neatly over the ruler, stack layers on a mat, and cut to 16 inches.

Outcome: Consistent strips to form the skirt’s depth.

2) Prepare the fold for double trim

• Fold lengthwise, letting the top layer extend about 1 inch over the bottom layer.

• Clip to keep the offset steady.

Outcome: A defined double layer that will show both ribbon trims cleanly.

3) Sew the elastic channel

• Load navy thread and bobbin.

• Fold a 1-inch seam allowance; sew a straight stitch to form the channel.

• Let the tulle fall into boxes to avoid lint and pet hair.

Outcome: A smooth, untwisted channel wide enough for 3/4 inch elastic.

Operation checklist

• Tulle cut to 16 inches

• Double-layer fold set with a 1-inch offset

• Channel stitched straight, no puckering hooping station for embroidery

Operation: Add the ribbon trim (double layer) 4) Attach the first ribbon side

• Load yellow thread and bobbin.

• Because the ribbon is single-sided, place the non-satin side up so the shiny side faces outward when flipped.

• Keep the ribbon’s left edge aligned with the presser foot’s left side to guide a straight seam.

• Heat seal ribbon ends before sewing to prevent fraying.

Outcome: The first ribbon edge sits evenly, with the shiny side showing when turned.

Pro tip (from the comments)

• Some makers combine hot glue and stitching on ribbon ends; the method here sews them together for durability.

Watch out

• Satin is slick. If it wiggles, use light clips or a touch of basting spray to keep the edge aligned. dime snap hoop

5) Secure the second ribbon side

• Flip the piece so the opposite edge is accessible.

• Again, place non-satin side up; lay tulle on the ribbon and sew as before.

Outcome: Matching double-ribbon trim, parallel and neat.

Quick check

• Both ribbon seams run straight and parallel.

• Ribbon ends are heat-sealed; no fraying.

6) Finish ribbon ends later

• You’ll sew ribbon ends together after the elastic is installed and the tutu is closed into a loop.

Outcome: Invisible, continuous trim. brother embroidery machine

Operation: Thread and close the elastic 7) Prepare and feed the elastic

• Cut 20 inches of 3/4 inch non-roll elastic.

• Attach a large safety pin to one end.

• Wrap the pin and the elastic tip with electrical tape to smooth corners and resist fraying (a workaround the creator adopted after fraying caused the pin to pop out).

• Secure the opposite elastic end under the presser foot with the needle down (machine unthreaded) to hold it while you feed.

• Begin threading through the channel, pushing gathered tulle along as you go.

Outcome: Elastic glides through without snagging, and the end won’t disappear into the channel.

From the comments (inline)

• Some crafters snip or round the elastic corners to help it slide. The creator reported that rounding still frayed; taping the tip worked better and prevented the safety pin from popping out. One commenter suggested heat-sealing elastic edges to combat fray; the creator uses non-roll elastic and was open to trying heat sealing as well. magnetic embroidery hoops

8) Close the elastic loop

• Remove the tape and pin; trim any excess.

• Spray basting adhesive on one end.

• Overlap elastic ends about an inch.

• Load white thread and bobbin; set a zigzag stitch.

• Zigzag multiple passes forward/back to secure both directions, then flip and stitch from the other side for strength.

Outcome: A sturdy, flat joint that won’t pop during play.

Pro tip

• Before stitching, double-check the elastic isn’t twisted. A quick run of your fingers around the waistband prevents surprises.

Operation checklist

• Elastic fully threaded, not twisted

• Ends overlapped and zigzagged securely on both sides Ricoma embroidery machine

9) Finish the ribbon ends

• Find both ribbon ends.

• Carefully trim excess without cutting into the tulle.

• Heat seal the fresh cut.

• Load yellow thread and bobbin; straight stitch across the overlap, backstitching to lock.

• Repeat for the second trim layer.

Outcome: A clean, continuous ribbon rim around the tutu.

Watch out

• Keep the tulle out of the seam while joining ribbon ends. Separating layers with your fingers before stitching avoids catching the skirt.

Operation: Embroider the birthday shirt 10) Set up for the appliqué and name

• Hoop the white shirt in your embroidery machine.

• Stitch an outline for the number “2,” place glitter embroidery vinyl over the outline, stitch down, and trim excess close to the seam.

11) Add Chase appliqué details

• Repeat outline–place–stitch–trim for felt pieces (face, ears, body, hat).

• Run the machine for detail stitching and the outline to bring Chase to life.

• Change thread colors as needed.

12) Personalize with the name

• Stitch the name “EVELYN” under the design.

Outcome: A crisp appliqué with glitter vinyl for the number, felt for the character, and a tidy name—ready to pair with the tutu.

From the comments (inline)

• Glitter embroidery vinyl was used here; glitter HTV also works—heat press afterward. Sourcing tip: glitter embroidery vinyl can be purchased from Etsy or kidscustomdesigns.com, per the creator’s notes. magnetic hoop for brother embroidery machine

Quality checks: Milestones to verify as you go

• After folding and cutting: Each strip measures 16 inches, with clean, square edges.

• After channel stitching: Seam is straight with no puckers; channel is wide enough for 3/4 inch elastic.

• After ribbon attachment: Satin sides face outward and both seams are parallel; ends are heat-sealed.

• After threading elastic: Even gathers all around; elastic is not twisted.

• After closing elastic: Overlap is fully covered with a zigzag, secured both ways.

• After finishing ribbons: Joins are flat; no tulle caught in the seam.

• After embroidery: Vinyl and felt are trimmed cleanly; outlines are smooth; the name sits level under the design.

Results & handoff: Finishing touches and care

• Pair the tutu and shirt and give the tutu a gentle shake to distribute gathers evenly.

• Inspect seams and trims one more time.

• Care notes: Hand smoothing helps the double ribbon trim lay pretty; heat-sealed ribbon ends resist fraying.

Troubleshooting & recovery Symptom: Tulle puckers while stitching the channel

• Likely cause: Tension too tight or uneven feeding.

• Fix: Test on scrap and dial tension to 4; let the fabric fall into boxes so it feeds smoothly.

Symptom: Ribbon looks wavy or misaligned

• Likely cause: Satin slid while stitching.

• Fix: Use the presser foot’s edge as a guide; add clips or a light basting spray to keep alignment.

Symptom: Can’t get elastic through the channel

• Likely cause: Sharp corners snagging or fraying.

• Fix: Wrap the safety pin and elastic tip with electrical tape to smooth the edges and prevent fray; secure the opposite end under the needle (unthreaded) so it can’t pull through.

Symptom: Safety pin pops out mid-channel

• Likely cause: Fray weakened the taped area.

• Fix: Retape the tip firmly. Some crafters round or snip corners; the creator experienced fray with that approach—taping proved more reliable. Consider heat-sealing the elastic edge as suggested by a commenter.

Symptom: Ribbon ends unravel

• Likely cause: Unsealed cut.

• Fix: Heat seal immediately after trimming; reinforce the join with a short straight stitch and backstitch.

Symptom: Embroidered appliqué shows raw edges

• Likely cause: Trimming too far from the tack-down stitch.

• Fix: Trim close to the seam after the tack-down and before the satin/cover stitch runs.

From the comments: Extra tips and answers

• Elastic threading tricks: Several makers suggested rounding corners; the creator had better luck taping the tip to stop fray and keep the pin secure. Heat sealing the elastic edge is another idea to try.

• Ribbon finishing: Some glue and sew their ribbon ends; the tutorial’s approach sews them closed for durability.

• Color and theme choices: One viewer recommended character-themed ribbon; the creator used what was on hand and chose Chase-colored accents to match the shirt.

• Glitter material options: Glitter embroidery vinyl was used; glitter HTV is an alternative—heat press after stitching the appliqué. Sourcing noted: Etsy or kidscustomdesigns.com. magnetic embroidery hoops for brother

Checklists recap Prep

• Materials gathered (tulle, ribbon, elastic, threads)

• Workspace clear; boxes set to catch fabric

• Machines ready; test tension on scrap

Setup

• Tulle cut to 16 inches; fold with 1-inch offset

• Straight stitch selected; seam allowance 1 inch; tension dialed

Operation

• Channel sewn straight; ribbon attached both sides

• Elastic threaded and zigzagged closed

• Ribbon ends finished; shirt embroidered with appliqué and name embroidery magnetic hoop