How to Embroider on Polyurethane Laminated (PUL) Fabric

Polyurethane Laminated Fabric, commonly referred to as PUL, is a polyester fabric coated with a shiny waterproof barrier. PUL fabric can be used in a variety of fun projects for children and grown ups alike. Because of the waterproof barrier, PUL is often used as a cloth diaper cover, for baby bibs, wet bags, rain gear, changing pads, diaper bags, and more.

Embroidering on a plain colored PUL is a great to way to make a handmade gift even more special. The waterproof barrier on PUL fabric means that additional steps are necessary if you want your project to maintain its waterproof character.

First, when embroidering on PUL fabric, be sure to use a ball point needle. My machine, a Brother PE-780D, does not require an embroidery needle, so a regular ball point needle will work with it. Make sure to change the machine's needle frequently so that the embroidery stays neat.

Next, decide what method you plan to use to back your PUL fabric to make sure that it stays waterproof. One way to back PUL fabric is to simply use a facing, or a double layer, of the same PUL fabric on your project. For instance, if you are making a waterproof PUL diaper cover, embroider on the outer layer of PUL. When assembling the diaper, use a second full layer of PUL on the inside of the diaper. The same technique can be easily used for bibs, changing pads, and other small projects.

However, if you are working on a larger project, or if you feel that a double layer of PUL is simply too bulky, it is possible to use a second layer of PUL to cover just the embroidered area of your project. This method requires a bit of planning when hooping the project in the embroidery machine, but the end result is a neatly covered and waterproof PUL project.

One way to hoop your PUL project is to use a sticky-backed tear away stabilizer. While a sticky-backed stabilizer works for some, I prefer to use a medium cut-away stabilizer when working with PUL projects. I find the results are neater and the designs stitch out more accurately.

In addition to the medium cut-away stabilizer, cut two smaller pieces of PUL fabric that are approximately one and half times the size of the finished embroidery design. Place the medium cut-away stabilizer on the hoop, then place one of the smaller pieces of cut PUL over the cut-away stabilizer shiny side down. Set the other small piece of PUL aside for now.

Next, center your PUL project on the hoop. Once your stabilizer, PUL piece, and PUL project are all centered on the bottom part of the hoop, firmly place the top piece of the hoop over the stabilizer and PUL sandwich and arrange all the pieces so that they are lying smoothly in the hoop. Use your embroidery machine to stitch your embroidery design.

Once your design is finished, remove the project from the hoop and trim off the excess stabilizer, leaving approximately one quarter inch of stabilizer around the embroidery design. Do not trim the small piece of PUL fabric backing the embroidery design.

Now place the extra small piece of PUL that was set aside earlier shiny side down on the back side of the embroidery design, matching the edges of the other small piece of PUL that was used to back the embroidery design. Stitch only the two small pieces of PUL together, hiding the stabilizer between the two small PUL pieces. Do not stitch the larger piece of PUL that you embroidered the design on. Now the back of your PUL embroidery project will be covered by the PUL, and the embroidery design will not wick.

After the embroidery design is sealed inside the PUL pieces, complete your project according to the project instructions.