How to Make a Puzzle Box Quilt: A Free Step-by-Step Quilting Tutorial

The photo above © Misty Doan

If you’re searching for a quilting project that’s both visually stunning and beginner-friendly, the Puzzle Box Quilt is the perfect choice. This quilt design features a woven, puzzle-like pattern created using fat quarters, making it a great way to showcase your favorite fabrics. In this comprehensive guide, we’ll walk you through the entire process, from cutting your fabric to assembling the quilt top.

Whether you’re a seasoned quilter or just starting out, this tutorial will help you create a beautiful quilt that’s sure to impress. Let’s get started!

Why Choose the Puzzle Box Quilt?

The Puzzle Box Quilt is a versatile and rewarding project for several reasons:

• Easy to Make: The large block design makes it quick to assemble, even for beginners.
• Customizable: Use your favorite fat quarters to create a unique look.
• Perfect Size: The finished quilt measures 55 inches square, making it an ideal lap quilt. However, you can easily adjust the size to make it larger.

Materials You’ll Need

Before you begin, gather the following supplies:

• 8 fat quarters (choose coordinating prints for a cohesive design)
• Background fabric (a solid color like navy or white works well)
• Rotary cutter, ruler, and cutting mat
• Sewing machine and thread
• Iron and pressing mat
• Quilting pattern (for reference)

Step 1: Selecting Your Fabrics

For this project, we used the Bold Color Story collection from Kaffe Fassett and Morris & Co., which features vibrant, iconic prints. Pairing these with a navy background fabric created a striking contrast.

When choosing your fabrics, consider the following tips:

• Use a mix of prints and solids to add depth and interest.
• Ensure your fabrics coordinate well to create a harmonious design.
• Divide your fat quarters into A fabrics and B fabrics for the block construction.

Step 2: Cutting Your Fabric

Accurate cutting is essential for a successful quilt. Here’s how to prepare your fabrics:

Cutting the A Fabric

1. Press your fat quarters to remove any wrinkles.
2. Cut 4-inch strips from your A fabric. You’ll need four strips per fat quarter.
3. Subcut the strips into 4-inch squares. Each strip should yield four squares, giving you a total of eight squares per fat quarter.
4. From the remaining fabric, cut two 4x11-inch rectangles.

Cutting the B Fabric

1. Repeat the pressing process for your B fabric.
2. Cut five 4-inch strips from your B fabric.
3. Subcut the strips into 4-inch squares and 4x11-inch rectangles, following the same method as the A fabric.
4. Additionally, cut 4x7.5-inch rectangles from the remaining strips.

Cutting the Background Fabric

1. Cut 4-inch squares and 4x7.5-inch rectangles from your background fabric. These will frame the print fabrics and create the woven effect.

Step 3: Assembling the Block

The Puzzle Box Quilt block is made up of a center unit and side units. Here’s how to assemble them:

Making the Center Unit

1. Sew a 4-inch print square (A fabric) to either side of a 4-inch background square. Press the seams toward the print fabric.
2. Sew a 4x7.5-inch background rectangle to a 4-inch print square (A fabric). Repeat this step to create two units.
3. Attach these units to the sides of the center piece, ensuring the seams nest together for a clean finish.

Making the Side Units

1. Sew a 4-inch print square (A fabric) to either side of a 4-inch background square. Press the seams.
2. Attach this unit to a 4x11-inch rectangle (A fabric). Repeat this step to create two side units.
3. Follow the same process for the B fabric to create two additional side units.

Assembling the Block

1. Lay out the center unit, side units, and corner units to form the block. The print fabrics should alternate to create the woven effect.
2. Sew the units together like a nine-patch block, starting with the top row, then the middle row, and finally the bottom row.

Step 4: Completing the Quilt Top

Once all your blocks are assembled, it’s time to put the quilt top together.

1. Arrange the blocks in a grid, ensuring the woven pattern flows seamlessly across the quilt.
2. Add 2.5-inch sashing between the blocks to create separation and highlight the design.
3. Finish the quilt top with a 2.5-inch outer border for a polished look.

Step 5: Quilting and Finishing

For this quilt, we used straight-line quilting with a plain angles design to complement the geometric pattern. However, feel free to experiment with other quilting designs, such as free-motion quilting or an all-over stipple.

For the backing, we chose a Morris & Co. print from the Kaffe Fassett collection, adding a pop of color and tying the quilt together beautifully.

Customizing Your Puzzle Box Quilt

One of the best things about this pattern is its versatility. Here are a few ideas to make it your own:

• Size it up: Use a larger fat quarter bundle to create a queen or king-sized quilt.
• Mix and match fabrics: Experiment with different color palettes and prints for a unique look.
• Add borders: Incorporate additional borders to make the quilt larger or add extra visual interest.

Final Thoughts

The Puzzle Box Quilt is a fantastic project for quilters of all skill levels. Its large blocks and simple construction make it quick to assemble, while the woven design adds a touch of sophistication. Whether you’re making it for yourself or as a gift, this quilt is sure to be a cherished keepsake.

We hope this guide has inspired you to create your own Puzzle Box Quilt. Don’t forget to share your finished project with us—we’d love to see your unique take on this pattern!

Happy quilting!

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Watch the Full Video Tutorial Here