ghostrider

I know this is a done deal, but I'd like to toss in some lessons learned that may help you for next time.

There are a great many variables in how fusible will behave in any particular case: the brand you used; whether your fabric was pre-washed and dried without fabric softeners; if it was applied according to the manufacturer's instructions for pressing setting, time and temp; what the humidity was at the time; how long it was allowed to set up; what type of fabric you used (print, batik, hand dyed); things like that.

I've been quilting with raw edge fusible appliqué for many years and almost never stitch along the edges now that fusibles have improved so much. In the few cases where I do, it's a fairly long straight stitch an eighth of an inch from the edge purely as a design element, never satin or zig-zag right on the edge. My work is not intended to be machine washed, but it is always wet blocked, gets folded fairly often, and travels, all with no ill effects on the edges.

Next time you want to try this technique, consider making two small samples. Stitch the edges of one but not the other. Toss them both in the washer and see what happens. Then try the dryer. You'll find out which way to go with much less risk than waiting till you've finished your project. I would also suggest writing down the results for future reference, especially if you wind up 'brand shopping' for 'your' perfect fusible.

Best of luck with the needle holes...especially the ones through three or four layers of fused fabric!