Making a Custom Banner or Flag

Lydia's "I Love Fall" Banner Pattern

Making a banner or flag can be a fun project for both adults and children. They can be done in elaborate designs or just using circles and squares. Sewn or glued together. Whichever way you decide to make your item it will be a custom design by you. The design directions below can be used for sewn or glued flags.

Many Fabrics can be used for indoor banners or flags however for those going outside I recommend Flag Cloth which is UV treated, mildew and rot resistant. We sell the DuPont Solar Max Flag Cloth and Foil Flag Cloth, used by Commercial Flag makers.

015-White	068- Off White	024-Flesh	037- Silver
064-Grey	003-Charcoal	020-Black	069 Seafoam
001-Aqua	076-Light Turquoise	030-Turquoise	077-Teal
065-Baby Blue	002-Process Blue	004-UN Blue	008-Old Glory Blue
006-Royal Blue	007-Peacock	035-Legion Blue	008-Old Glory Blue
070-Dark Navy	010-Mint Green	011-Green	012-Emerald Green
013-Forest Green	075-Olive	066-Peach	062-Salmon
027-Buff	022-Gold	028-Tan	063-Rust
080-Golden Brown	026-Kakhi	029-Brown	082-Lime
025-Yellow	028-Daffodil	021-Spanish Yellow	023-Golden Poppy
014-Int. Orange	019-Orange	036-Pink	031-Orchid
032-Magenta	081-Crimson	016-Warm Red	079-Bright Red
017-Canada Red	018-Old Glory Red	033-Wineberry	040-Burgundy
067-Mauve	038-Lilac	039-Lavender	034-Purple

Nylon Metallic Foil Flag Cloth is 45” wide and has foil on one side only, back side is white knit fabric. Comes in Gold (item #050072) and Silver (item #050071). Cost is $13.99/ yd

If you are going to sew your flag you will need to consider the type thread you use to construct your flag.

I use polyester embroidery thread. It is colorfast, holds up outdoors and is easy to work with if you are going to stitch around a design. Since it comes in many colors there is always one that will match the color of the cloth you are using. We sell Sylko Embroidery Thread and Mettler ( Embroidery Thread) and can match the thread to the flag cloth colors.

The first step in making a banner is deciding on the design you want and the size of the banner or flag. Usually I start the design with a solid background color the finished size of the flag plus seams needed (see finishing section below). Once you decide on the flag size you will need to size your design to fit the flag size. I make a good picture or design and then go to a copy center and get the design resized. However you can also use grid patterning paper (item #040040) and resize the design as desired.

After the design is the correct size I cut each piece and position them on the flag with temporary spray (505 item # 090438). See Appendix 1 if you are sewing down your design and the design to show on front and back of flag. See Appendix 2 if you are gluing your design.
If my design includes letters or numbers and I am going to sew the design in place I normally do not cut them out at this time. Even though it uses more fabric, I trace the letters or numbers as I want them to appear on my banner and then position this larger piece of fabric on the solid background piece and stitch around with the narrow zig zag mentioned below. Then trim off excess fabric and proceed with the wider zig zag. This saves a lot of time. Remember letters or numbers will be incorrect on the wrong side of the flag.

If I am sewing a design in place I decide the order the pieces need to be sewn to give me the dimension I want for the finished look. I first go around the piece with a narrow zig zag stitch with a stitch length of 2.5-3.5. After this I do a dense zig-zag with a wider width to give it a nice satin stitch look around each piece. You may need to reposition a piece as you go so again use temporary spray to keep it in position so it does not shift as you stitch your design down.

Mark 1” in from edge around the flag on the right side of fabric along the 3 sides of the flag, which will be the edges when finished. Turn under on the mark line and stitch close to the edge. Turn the flag over tuck in the raw edge evenly and do a second row of stitches along the new hemline. This gives you an even double needle look on the edge.

The fourth side (side that hangs the flag) can be finished a number of different ways depending on your application for the flag or banner.

2) Pocket top: Form a pocket at the top with tabs for placement of a hook. Decide how large the pole will be
to determine the pocket size. And add a tab with a buttonhole for the hook if the pole comes with

3) Grommets: Fold in raw edge and place between two pieces of 1î polypropylene webbing and stitch around all 4 sides.(we have 12 colors of polypro webbing at $.20 per foot in stock). After sewing place grommets about 1" in from both ends. If the banner is wide you may need additional grommets depending on how you are hanging the item.(we sell grommets and tools).

Think through any other ideas you have and then creatively implement them. (tabs at top, line, buttonholes etc.)

1) You can make 2 identical flags and sew then together like a pillow case with right sides together and then turn right sides out and stitch around the border of the flag to stabilize it. This is often done when you have numbers or letters.

2) Or after stitching the design with the narrow zig zag mentioned above you can trim out the base fabric on the reverse side of the design and then proceed with the wider zig zag. This is how many commercial flags are made however this is a weakened area if your flag hanging in very windy conditions.

3) Or sew extra piece of fabric on the back side when you are sewing fabric piece on the front. This is done after setting up your design on the front side. You lay a fabric piece on the back the same color as the front piece positioning it over the front piece. You then sew with the narrow zig zag mentioned above on the front side of the flag or banner. Trim off excess fabric on the back side and around this piece with the wide satin stitch mentioned above.

Purchase fabric glue. Test a piece of flag cloth. After setting up your design glue each piece in place.