Table of Contents
- Primer: What Tutu Boards Do (and When to Use Them)
- Prep: Tools, Materials, and Workspace
- Setup: Dimensions, Rationale, and Safety
- Operation: Cut, Size, and Label Your Boards
- Quality Checks: Consistency You Can Trust
- Results & Handoff: Your Organized Board Library
- Troubleshooting & Recovery
- From the comments: Sizing sources, usage, and sales
Video reference: “Creating Tutu Boards for Sweet Threads Baby” by the creator.
If you make tutus for gifts or an Etsy shop, speed and consistency are everything. This guide shows you how to build durable, pre-measured foam core boards so you can wrap tulle quickly with repeatable results—newborn through size 14—without guesswork.
What you’ll learn
- Why pre-measured boards accelerate production and consistency
- The exact width to cut your base boards, plus a newborn length example
- Tools and workspace setup for straight, safe cuts
- A labeling system that prevents mistakes during busy batch days
- Community tips on sizing sources and next-step sample builds
Primer: What Tutu Boards Do (and When to Use Them) Pre-measured tutu boards—also called tulle boards—are foam core templates cut to a standard width and size-specific lengths. Wrap your 6-inch tulle around a board, cut once, and you’re left with consistent strands ready to tie or attach for traditional tutus.
Why they matter
- Consistency: Every strand is the same length for smooth, even tutus.
- Speed: Batch cutting on boards is far faster than measuring strip-by-strip.
- Memory aid: Labels keep sizes straight when you’re juggling orders.
When to use
- Any time you’re making multiple tutus across sizes (newborn through size 14 were created in this project).
- During seasonal rushes or production days when setup time must be minimal.
Context for craft sellers The creator is developing “Sweet Threads Baby,” relisting a large inventory after a slow post-holiday period (a common, seasonal pattern), and starting sample tutus. A labeled, reusable board set supports that scale.
Note on sizing sources Viewers repeatedly asked for exact sizes. The creator credits a community resource—“Sheryl and Fam”—for measurements she follows. This tutorial focuses on the board system (with a newborn example length) so you can build your workflow and integrate your preferred sizing chart.
Pro tip If you pair tutus with embroidered tops for sets, standardize your apparel workflow too. A simple gear upgrade like hoop master embroidery hooping station can keep shirt placement consistent while your tulle cutting runs in parallel.
Prep: Tools, Materials, and Workspace What you need
- Foam board: Choose thick foam core for durability; it resists warping and lasts in daily use.
- Cutting mat: Protects your surface and helps square up cuts.
- Rotary cutter: Use an old blade dedicated to foam; foam will dull it quickly.
- Quilting ruler(s): Long, rigid rulers keep cuts straight and fingers safe.
- Permanent marker (e.g., Sharpie): For bold, legible labels.
- Optional: Tripod or stand if you like to record your process for content or QA.
Workspace setup
- Clear your cutting area. Turn off distractions so you can stay precise.
- Place the foam board on a mat with ample overhang for the rotary cutter to exit safely.
- Keep the marker nearby—you’ll label each board immediately after cutting.
Watch out Rotary cutters are extremely sharp. Keep fingers fully on top of the ruler, never creeping along the blade path.
Quick check Before the first cut, confirm your tulle width: this system is built around 6-inch tulle.
Checklist — Prep
- Thick foam board on a cutting mat
- Old rotary blade installed
- Long quilting ruler within reach
- Marker uncapped and ready
- Tulle width confirmed at 6 inches
Setup: Dimensions, Rationale, and Safety Board width - Base width: Cut boards to 8 inches wide. This extra over the 6-inch tulle gives you finger room and stable wraps without snagging the edges.
Board length
- Example shown: Newborn length of 13.5 inches.
- Other sizes: The final set covers newborn up to size 14; lengths follow the sizing guide the creator uses (“Sheryl and Fam”). Apply your preferred chart to generate each board length.
Why the old blade? Foam dulls cutters. Retire a sharp blade to foam duty, and keep a pristine blade for fabric.
Safety basics
- Cut with firm, even pressure against the quilting ruler. Don’t rush the stroke.
- Reposition the ruler rather than overreaching—long boards make overreach tempting.
Community note on measurements Multiple viewers asked where to find exact sizes; the creator repeatedly cited “Sheryl and Fam” as her source. Use one solid reference for your whole set to avoid mixing standards.
Pro tip If your studio also handles embroidery orders, store your ready-to-wrap tulle bundles next to your hooping area. Magnetic frames like magnetic embroidery hoops can speed up shirt add-ons while tutu pieces stay organized by size.
Checklist — Setup
- Width target: 8 inches
- Newborn length noted: 13.5 inches
- Full size list on hand (from your chosen chart)
- Safety stance and hand positions practiced
Operation: Cut, Size, and Label Your Boards 1) Rip boards into 8-inch strips
- Place the long edge of the foam board on the mat.
- Align the quilting ruler at 8 inches; double-check at top and bottom.
- With your old rotary blade, cut smoothly along the ruler’s edge. Repeat to create multiple 8-inch strips.
Outcome you want: Clean, parallel edges with no ragged foam. If edges crumble, apply steadier, even pressure and ensure your blade isn’t past its foam-duty life.
2) Cut to length for your sizes
- Start with newborn: measure 13.5 inches and cut.
- Continue: use your size chart to mark and cut additional lengths from the 8-inch strips.
Watch out It’s easy to invert a board and measure from the wrong end—always align the squared factory edge or freshly squared edge with your ruler before marking length.
3) Label immediately
- On each board write: size (e.g., “Newborn”), width (8"), length (e.g., 13.5"), and the number of tulle strands for that size if your chart specifies it.
- Use large, legible writing so you can read labels at a glance, even stacked.
Outcome you want: Every board clearly marked before it leaves the cutting station. No unlabeled boards migrate to storage.
4) Batch production rhythm
- Cut several 8-inch strips first, then switch to length cutting in a focused block.
- Label as you finish each length batch to avoid mix-ups.
- Periodically stack finished boards by ascending size to confirm coverage from newborn to size 14.
Decision points
- If your tulle is 6 inches wide (as used here) → keep board width at 8 inches.
- If you use a different tulle width → adjust board width to provide about 2 inches of operating clearance beyond tulle width (example rationale based on the 6 to 8 approach used here). Apply the same clearance logic consistently across sizes.
Quick check After cutting your first three sizes, stack and verify labels read in order. Visibility matters when you’re mid-project.
Checklist — Operation
- 8-inch strips cut cleanly
- Newborn length cut (13.5 inches) and labeled
- Additional sizes cut per your chosen chart
- All boards labeled before storage
Quality Checks: Consistency You Can Trust At each milestone
- Width audit: Randomly measure completed strips; they should read exactly 8 inches across.
- Length audit: For each size family (baby, toddler, big kid), spot-check one board’s length against your chart.
- Edge integrity: Run a finger lightly along the cut edges—no crumbling or flares.
- Label legibility: Can you read the size and length from an arm’s length away?
Quick check Stack your boards. A well-made stack sits square without fan-out—miscuts often reveal themselves as a fanned stack.
Pro tip If you concurrently prep embroidered tees, batch your shirt placements while boards are cooling on the table. A tool like dime snap hoop can accelerate on-off hooping in between foam cuts.
Results & Handoff: Your Organized Board Library What you should have
- A complete, labeled set of tutu boards spanning newborn through size 14 for traditional tutus.
- Boards organized by size, ready for wrapping sessions and sample builds.
Storage ideas
- Store vertically in a bin or horizontally on a shelf—labels outward for quick grabs.
- Keep the marker clipped to the bin so any replacement or edit happens on the spot.
Community question: Will these be sold? A viewer asked if extra sets would be listed for sale. The creator responded that she is using them to make tutus right now.
Handoff to making tutus With boards done, your next session is all about wrapping tulle, cutting clean bundles, and assembling traditional tutus. The labeled dimensions mean you can stage multiple sizes for a production day without re-measuring.
Troubleshooting & Recovery Symptom: Edges crumble or fuzz
- Likely cause: Dull blade or too much lateral pressure.
- Fix: Replace the old blade with another retired blade; keep pressure straight down along the ruler.
Symptom: Widths inconsistent across strips
- Likely cause: Ruler drift during long cuts.
- Fix: Use a longer quilting ruler, anchor with firm hand placement, and cut in passes rather than pushing too hard in one go.
Symptom: Lengths off by 0.25 inch or more
- Likely cause: Measuring from a beveled or uneven edge, or misreading the ruler line.
- Fix: Square one end before marking. Double-check length at two points and score lightly before the final pass.
Symptom: Labels smudge or fade
- Likely cause: Non-permanent pen or handling before ink dries.
- Fix: Use a permanent marker and pause briefly after writing.
Quick tests
- Square test: Place two boards side by side; edges should align perfectly top and bottom.
- Read test: From standing position, confirm size text is readable without lifting the board.
Pro tip If you maintain both garment and tutu workflows, keep a compact embroidery setup nearby, such as a brother embroidery machine with simple presets. While foam boards dry from labeling, you can run quick appliqué or monograms for bundle listings.
From the comments: Sizing sources, usage, and sales Here’s a distilled set of community Q→A integrated into this guide:
- Where do I get exact board/tutu measurements? The creator consistently cites “Sheryl and Fam” as the sizing source she follows.
- Can you share sizes up to 14? Sizes up to 14 are covered in her set; measurements referenced come from the same source above.
- What about number of tulle pieces and elastic waist sizes? She follows the “Sheryl and Fam” guide for these variables as well.
- Will you show how to use the boards? Yes—she confirmed she would show usage in content.
- Will you sell board sets? She’s using her boards to make tutus at the moment.
Pro tip When your listing photos need a lift, align your apparel accessories workflow with your tulle schedule. If you already use magnets in your hooping routine, magnetic hoops for embroidery machines can reduce shirt changeover time so you can keep momentum on tutu wrapping.
Watch out Pets and crafting don’t mix. A loose baby gate once led to scattered fabric and thread. Secure your workspace when you step away.
Studio rhythm add-ons
- If you’re just adding embroidery to your product mix, look for an embroidery machine for beginners that fits your budget and space. Pair it with a simple hooping station for embroidery to standardize placements while your tutu boards do the consistency work for tulle.
Wrap-up You now have a durable, labeled, and organized tutu board system: 8-inch width, a demonstrated 13.5-inch newborn board, and a structured workflow to expand through size 14 using your trusted sizing source. This is the foundation for reliable, fast tutu production—and calmer studio days.