Terribly sorry this happened. I am now afraid to wash anything quilt related.
If you are in any kind of a guild or bee, maybe there is someone you could ask. You could even try a LQS or a long armer for suggestions.
I would rather not speculate on what caused it - I am not really sure where to begin.

I’m so sorry this happened to your quilt, Julia. You worked so hard on it and were very excited to have it done a month ahead of time. I’d be in tears and angry about the poor quality.

I think you’re wise to have started over. Poor quality covered up is still poor and might rip worse with time and washing. Besides, putting appliqués all over it might not be comfortable.

You’ll be fine. Deep breaths. Practice the ole Lamaze breathing —heeheehhoohoo, heeheehoohoo.

So sorry this happened to you but how fortunate that you washed it before gifting. I would start over too, if I were you. I'm sure you have made enough quilts to know your quarter inch seam is not the problem.

I have finished enough HST's for 4 blocks already. I will start squaring them up tomorrow and then try to get another 4 blocks Sun or Mon. Slowly but surely I will get it done and before the baby is born.
I will show off the new quilt when it is done, and washed, which should be soon.

Just wanted to say I am sorry this happened.

How disappointing and disturbing! I think you are right to start again and use this one for a different purpose. The applique idea is a good one if the rest of the seams and fabrics will hold up … or will it happen again with the next washing?

So sorry to hear that this happened. I would still contact the manufacturer. They can't repair the quilt but you may be compensated some how. Not that you want to be, it's heartbreaking. Glad to hear you are already on another one, baby quilts get alot of washing.

So sorry for your disappointment. Best wishes on stitching a new one. Glad you discovered the fabric issues now.

Not all is lost on the beautiful quilt. Check our Kelly Cline and Rhonda Dort. They will take a vintage piece with holes and cover with doilies or a piece of vintage embroidery. Lovely! Good luck to you.

That is beyond frustrating! I would start over as even if you fixed it with some appliqué, it could happen in other areas with more washing.