2 1/2" is the best I can do, anything smaller, don't even want to try.

I have been and likely will be a 2.5 gal, but in the past months while working on the Harriet's Journey sampler, I have done some work with 1.5 and actually enjoy the challenge. I am not an accurate piece maker but on the other hand 1.5 makes seam ripping petty easy.https://cdn.quiltingboard.com/images/smilies/smile.png They don't scare me like they used to.But, not ready for one of those OMG quilts that are all wee bitty pieces. https://cdn.quiltingboard.com/images/smilies/eek.png

Just finished making a postage stamp block with 1/2" squares. It was fun but crazy. Stuck it up on my design wall and walked away. It's like going down a rabbit hole when you work that small. I think nesting the seams is important as well as an accurate scant 1/4" seam. The reason for the scant 1/4" is for the turn of the cloth; the few threads that are taken up when opening the seam once it's sewn. Working with small pieces can be done but it takes time and patience. Or, if you're like me, some mean bull dog determination.

omg! I spent last evening designing a pixel art quilt for 1 inch squares! I finished my practice top of a simple seahorse. I used an old counted cross stitch pattern that I dusted off! I used 1.5 inch squares, but they make it seem too juvenile/minecraft-y. so, the next one will be 1 inch squares.

I often make 4" finished blocks using 1.5" squares and rectangles. I don't seem to have an issue keeping these aligned and true. I make sure my seam is an accurate 1/4" and use a sewing ledge. I just finished a Leader Ender project that used 1.5" squares and rectangles and made 300 finspished blocks during 2020. The Leader Enders were completed while making the School Girl Sampler which also fins in at 4". Blocks larger than 6" seem HUGE to me:-)

I try to tell myself that a 1/4" seam is a 1/4" seam no matter how much or how little fabric there is on the other side. But I start feeling pretty clumsy after about a 2" cut. One of my issues with the Bonnie Hunter Mysteries (other than why so many triangles!) is I just don't think a 1" finished square is really appropriate for the size of a queen+ sized quilt.

My solution to accuracy is cutting large and trimming down anyway. I wouldn't be doing this sort of thing on $12 a yard fabric, but from my stash and if I'm working on scraps, if it makes me feel less clumsy and is quicker/easier, and I'm not going to be able to use my trimmings anyway, yeah -- why not take two 2.5" jelly roll strips, sew them down the middle and then trim them to the correct width. even if you are trimming off an inch or 3/4". Always remember your seam allowance!

I've only done one quilt with very small pieces (an Elizabeth Hartmann). It was very difficult. I used a seam guide and got thru it, but tiny pieces are not my favorite. I'm good with 2 1/2 inch squares but 1 1/2 are awfully small. Depending on what pattern you are doing, it could be possible to use 2 1/2" squares and just have a larger quilt.

Anyone remember the Keepsake Quilts sample boxes? You could get a 1" square of every new fabric line in the store for that year. It came in a little square green box. I nine of these boxes I bought a an estate sale. Hundreds of tiny squares. Each one different. I may start a miniature postage stamp quilt.

I always use a fairly small stitch (1.8) when doing small squares and pressing and nesting the seams is really important. I have learned about making small squares from doing the Bonnie Hunter mysteries and look at them as an opportunity to improve my piecing, pressing, and general quilting. The hint she provides during the mystery's are very helpful on everything from cutting out the fabric, to pressing, to nesting the seams, and keeping everything organized. Yeppers, Bonnie's mysteries end up being a bit on the heavy side because of all the seams. Early on, I decided not every point would be perfect nor every seam perfectly lined up and that I would focus on doing my best and the most amazing thing has happened. Now most of my points are decent and most of my seams actually meet and the finished quilt is pretty close to the size it is supposed to be. I do sometimes quilt the bonnie quilts denser because I want to make sure all the seams are nailed down....I usually just follow her color scheme so I can concentrate on the piecing skills. Oh, and some of my machines are really better at piecing small pieces then others. I use a straight stitch plate always when piecing and I will switch to my walking foot for attaching long rows, borders, binding as that helps feed the fabric more smoothly on top and bottom.

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Somewhere I have a 15x15 square my grandmother started as a postage stamp quilt. She was an avid quilter but that's as far as she got. It became a doll quilt for me. Pieces were about 1 inch x 3/4 maybe?