I made 2 baby puff quilts this winter. I didn't have a pattern.
1. I cut the base squares at 4 inches.
2. The top squares were 4.5 inches.
3. I used 1/2 cup of poly-fil to stuff the puffs. I measured the ploy-fil because I wanted the puffs to be pretty uniform in size (puffiness).
4. Take a square of muslin and place your fabric right side up on the muslin.
5. Sew three sides of the muslin/fabric layers using a seam allowance smaller than 1/4 inch. Make pleats near the center of each side as you sew.
6. Stuff the pillow with 1/2 cup of poly-fil, then sew up the last side. Whatever size you decide on don't stuff the puffs too much or it will become very difficult to sew them together.
7. After sewing all the puffs, I laid them out on a flat surface to position them in a pattern. These happened to be random.
8. Sew the puffs into strips, using a 1/4 inch seam allowance. (making the finished puff 3.5 inches).
9. I finished the 2 quilts differently. One method is to sew all the strips together into one piece. Prepare your back by measuring it to the same size as the quilt top. Place the back and top right sides together and sew around the quilt, leaving a space to turn the quilt right side out. After turning, finish the seam by hand. I then did some spot hand stitching to anchor the back to the front so that it would not flap around.
The other method is a little more compicated. I sewed the strips into pairs. This made larger strips of 7.5 inches. I cut the backing into 7.5 inch strips and attached the backing as I sewed the paired strips together. This leaves all the outside edges unfinished. I used a pre-ruffled (I think that it was Wright's) quilt binding to finish the edges.
You can make the squares any size you want. Just don't stuff them too full or you will have trouble joining the strips.
Hope this helps. If you need more info I'll see if I can help
Alice
Here are some links that I found helpful
http://www.quilterscache.com/P/PuffQuiltingBlock.html
http://www.womenfolk.com/quilt_pattern_history/biscuit-quilt.htm
http://www.patchwork-quilt-patterns.com/html/how_to_make_a_puff_quilt_.html
http://my.homewithgod.com/barrowood/quilt_instructions2.htm