Are you pinning your binding to the quilt sandwich before you sew it on? I don't. I almost always use bias cut binding; just my personal preference. I think it just hugs the edge of the quilt better than straight of grain. I also use diagonal joins. When I am sewing my binding to the top of my quilt sandwich, I lay the binding on the top and start sewing it on. As I am sewing, I will just keep laying the binding on top of the sandwich without pulling or stretching it. I stop 1/4" from the edge and then I do use a couple of pins to place my corners correctly. Works for me and I haven't had any issues with puckers. I also make sure that I don't have any joining seams anywhere near the ends of my binding.

I loosen the tension on the presser foot. My default is 6, when I work with walking foot, I loosen to 4. I use straight grain cut, diagonal joins...so far no puckers... But I also do NOT tug as I sew, just lay together and let walking foot keep layers going together.

Funny, I was going to recommend that you maintain a firm hold on the binding when sewing it on. I don't mean stretch the life out of it, but just hold it firmly as you sew. When I don't do this I get puckers. To each his/her own! Ann

I take a few seconds and pin the binding to the quilt. When I sew the binding on, I do provide a bit of tension. I don't have puckers.

Another thing - don't iron your binding in half. It actually wraps around the raw edges of the quilt better if you don't.

Try a walking foot. I hope you find the solution to this. That is frustrating.

This does happen to me on occasion also. When you fold it over you cant see it.

I think on my next binding I am not going to iron it in half.

I am assuming that the method you are talking about is joining the two ends of the binding with a seam before it is attached to the quilt. when I have tried this I was not happy with the results for the same reason. I start my binding with a good 1/2 inch folded back like a seam allowance on a bias angle. Then I attach the balance of the binding to over lap my seam allowance at the start, fold back as before and finish. Then I hand stitch the join before turning the binding to finish.

Perhaps this will work for you as it does for me - only pin first 6" or so of the binding to the quilt. Continue just laying the binding onto the quilt as you sew. You can pin 6-8" ahead as you go. I learned not to measure and try to fit binding. Leave long and just "lay it on". Never ever had a wrinkle or pucker this way!

I sew my ends together with 1/4 inch shorter than they should be. This will take care of the extra you get when sewing. Just have to pull it taut while sewing that last bit down. It works well for me.