A recommendation I have seen for flannel, aside from prewashing and drying a couple of times, is to use 1/2" seams whenever possible for piecing. For use as a backing, I have even seen a recommendation of 1" seams for flannel.

I just bought a set of flannel sheets to use as backing for a couple of quilt tops, and now I am worried about the wear qualities of flannel. The color is perfect for the quilts I had in mind. At least I don't have to worry about seams in the backing pulling apart.

I was also thinking seam size might have been the issue in this case. Since flannel is a looser weave, its seams could experience more stress.

When I use flannel for a backing I wash and dry it several times. I sew one-half inch seams and sew them twice. I would not use flannel in a quilt-as-you-go quilt. Too many small seams and many not always end up as 1/4 inch.

Have you considered that minky
will make it heavier and might be too heavy.

What a dilemma. It seems that we take so many chances in quilting concerning our components.

Thank you, again. I really appreciate your wisdom. Great idea to use larger seams and to not use it for a QAYG. I think that sewing twice a 1/16 inch apart might be good too. As far as adding the Minky. It will make it quite a bit heavier, however, she was 7 when I made the original and she is now almost 13. I believe the weight will be okay for her age.

Unfortunately, I cannot remember which thread I used. Need to add that to my journal because it may be best to use a thicker cotton thread on flannel.

It may not have necessarily been the fault of your work or the materials. If the family has a dog who gets on the quilt and digs around with his claws, as many will do, that might be the explanation. Even if they're sure their dog never gets on the bed, there are plenty of videos on Youtube showing crafty dogs hopping up as soon as the owner leaves the house. That's just one theory. Whatever the reason, I think your solution will work well.