Oh, I hate this for you!! It is so heartbreaking when this happens. I am also glad you washed it before you gifted it (something I will start doing from now on). I agree with the others about the flannel, and I wanted to send you some positive vibes. I agree that adding strips should work.

Sometimes this happens if I use a stitch length that is too long or SA is too narrow even when I'm using a good quality quilt fabric. I get a litte careless at times. When I get s SA that I think is too narrow, I stitch a second seam right next to the first on on the seam allowance side in a very short stitch length.

I'd be upset too if a quilt came out of the dryer looking like this. I always wash a quilt using the harshest setting that I think it might encounter...like for a child, or an elderly person...to see if it'll hold up before giving it away.

I've seen this happen during the pressing stage when poly thread was used.

Oh my, I would have been just sick too!! Thanks for sharing. I don't use much flannel, usually just for backing.

Yikes, sorry that you had that experience. I have only used flannel on backings of crib quilts.

thanks everyone.. maybe I have never made a flannel quilt.. except for backing.

I did put o patches and gave I to my nephew He didn't seem to care or even notice :) Of course I am a little worried how my patches will hold up-used the same fabric. that was nice because it matched though Tim will tell

I would say not a good fabric choices for that type of sewing.

Oh, no! I have used flannel many times and only used a 1/4 inch seam! No one has complained - yet.

But, with flannel, I pre-wash and dry twice so that it shrinks before I make the quilt. I also use a denser quilting motif to keep it together. The fabrics/batting shift less when washing when more densely quilted.

That's my story and I'm sticking to it!

Another factor could be that the unwashed flannel (because it was layer cake squares) shrank far more than the batting and backing which would make it pull out of the seam. I hope you patching project works out. I think flannel is a bit difficult unless it is prewashed. Better luck next time!