The only thing I do different with flannel is wash it before I cut. Also, I will not buy cheap flannel. It is thin, stretches terribly when you are sewing and shreds. The flannel I get is from my lqs, The Cutting Edge. I'm not sure what brand, but I made pj's for my oldest grandson (12) that my youngest (5th) grandson (1 1/2) is now wearing. They are a little faded, but have gotten softer with age. There is not one pair that has torn and believe me they have had a lot of use and a lot of washing.

I always wash in hot water, and dry in hot dryer to shrink as much as it will before cutting. Due to its propensity to ravel extensively, I use a very narrow zig zig stitch instead of a straight stitch and a slightly larger seam allowance (make sure you take this into account before you cut). I have made PJs about 10 years ago for one Grand daughter that have been passed down to middle sister that youngest one is now wearing....they are softer and slightly faded, but still holding strong.

I sew it just like everything else. I do wash it first to shrink it.

do wash it first.