Making Bold Moves with Aurifloss
I love when hand quilting takes center stage—when it shines, makes a statement, and holds its own. For me, why not try the thickest thread I can manage. Enter: Aurifil Floss.
To be honest, I was hesitant at first. I hadn’t considered this thicker, 6-strand thread for hand quilting until recently, when I was playing with a few tester Sweet Mae blocks and decided to turn them into a bag. I wanted to highlight the sawtooth star design, and a bold hand-quilted stitch line felt like the perfect finishing detail.
That’s when I grabbed my spool of Aurifil Floss in a vibrant green 2882 Light Fern it matched my AGF Evelyn's Green Thumb print beautifully. And since I was only quilting through the top and batting (no backing, thanks to the bag construction), it felt like the perfect low-stress opportunity to try out this floss for hand quilting.
Do you see the quilting inside the sawtooth star? It’s subtle, but it’s there.
I paired it with the creamy brown 40wt Aurifil 2340, Café au Lait, a warm shade that falls between beige and soft taupe. I used it for machine quilting to add a layer of texture and contrast.
What I Used
As always, I stuck with my trusty size 1 needle. It has a generous eye—meaning the opening that holds the thread—which makes threading thicker floss less frustrating. It’s also long and sturdy, which is ideal for my larger hands and thicker thread.
Curious about the tools and methods I use for hand quilting?
👉🏼 Check out my free Hand Quilting Guide or join Quilting Compass to gather more downloadable quilting guides.
Why I Love Aurifil Cotton Floss for Smaller Projects
These blocks were part of a project for my niece’s birthday—Sweet Mae is actually named after her! I broke up the baby-sized version of the quilt (four blocks) to make dual gift: a doll sleeping bag and a smaller quilt just Maggie’s size.
The fabric I used for the pattern cover is a 100% woven from Fableism, paired with bamboo batting, which gave the quilt incredible drape. Wovens are already soft and flexible, so pairing them with hand quilting—and especially something smooth like Aurifil Floss—adds the most delicious texture.
You can grab the Sweet Mae quilt pattern and fabric bundles here. Pattern release July 2025.
Mixing Thread Weights for Texture
One of my favorite ways to quilt is by mixing thread weights:
Machine quilting first, in this case, vertical lines using Aurifil 50wt 2310 Light Beige.
Then layering in bold, horizontal hand quilting lines using colors of Aurifil Floss 2215 Peach, 6731 Tiramisù, 2515 Light Orchid — what I snagged from my Aurifil Artisian Welcome Package. (see below
PRO TIPS: By machine quilting first it…
Built-in basting by locks the quilt in place, so you can hand quilt freely without glue or pins.
It creates a layered texture that you just can’t get any other way.
Let’s Talk Technique
Here are my quick tips for hand quilting with Aurifil Floss:
Use shorter thread lengths – about 8"-10" helps reduce tangles and twisting.
Avoid thread gloss – in my experience, it adds drag and can pull batting through more easily.
Knots – I wrap the thread three times around my needle for anchoring along the binding, 2 times for mid-quilt endings. For quilting cotton fabrics, a single or double wrap is ideal to prevent the knot too thick to pop through.
Go slow through seams – If you’re crossing bulky intersections, try one stitch at a time using a rocking motion.
Stitch rhythm – On flatter areas, I usually load 3–6 stitches on the needle before pulling the thread through.
Becoming an Aurifil Artisan
Aurifil has been my go-to thread since launching Zahm Co. My earliest quilts? Probably some other brands in high school—but since going pro, it’s been Aurifil all the way. The Italian quality is unmatched. Maybe it's my newer last name (Aufiero) or it's the colors and reliability, but it just feels like home.
Being selected as an Aurifil Artisan this year? Honestly, it’s a dream come true. I've wanted this for years.
My husband even jokes and calls me “Katie Aurifil” now. I’ll take it.
I believe in timing. I believe in preparation meeting opportunity. That’s where luck lives, and I feel lucky to be living this right now.
Click here to watch me open my welcome package—or check out the silent version on the left without music or commentary.
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Ready to Try Floss Yourself?
If you’ve been curious about adding bold, high-impact hand quilting to your next project, Aurifil Floss is a fantastic way to start—especially on smaller projects like pillows, bags, or wall hangings.
You can grab the Sweet Mae quilt pattern here, or explore more hand quilting techniques and projects inside The Quilting Compass.
And don’t forget to tag me @zahmco if you try floss for the first time—I’d love to cheer you on.