InnerFuse™ Jack-o-Lantern InnerFuse™ Jack-o-Lantern
Designed By - Mark Lipinski

There is no easier project for Halloween than this adorable Jack-O-Lantern created with InnerFuse™. From start to finish in less than 2 hours, this candy filled friend will delight trick-or-treaters both old and young. Use the simple pattern formula and make your pumpkin in any size!

General Crafts category

Time to completion: 2 hours

Skill level: 3 of 5, 1 being the easiest


Materials List  

5– 14" x18" InnerFuse Sheets – Heavy Weight (or 2 ½ yards from bolt)
1 ½ yds – Orange fabric (pumpkin body and lid)
2 yds – Black fabric (pumpkin lining, lid lining, and face)
1 Fat Quarter – Green fabric (leaves)
1 pkg - Dritz ® Ball Point Machine Needle – Size 14/90 (# 58-90)
1 – Dritz Awl with Protective Sheath (# 624)
Sewing Machine – with zigzag stitch

1 each – Orange, Black, and Green thread
1 each – Orange, Black, and Green permanent marking pen
Hot Glue Gun and Glue Sticks
Green Heavy Gauge Craft Wire
Pinking Shears
Raffia ( optional )


Determining the Jack-O-Lantern Size

The formula for creating the 36” x 18” pumpkin is very easy. Four template panels zigzagged together will create the rounded shape. To create a different size, use the formula below to draw the templates needed. (Our measurements are in parenthesis)

Jack-O-Lantern circumference __(36)_____
Divide circumference by 2 _ (18)_ ( pumpkin template length- figure A)
Divide circumference by 4 (9) ( pumpkin template width-figure B)

Making the Jack-O-Lantern Template

Using the formula and referring to figures A & B, draw the pumpkin template using card stock or template plastic. Measure 4" down from one end of the template and cut across width. (figure C). This is your completed pumpkin template. (See template shape included. This is NOT a pattern)
*Adjust the cutting line for a smaller or larger pumpkin.

Cutting Instructions:

From orange fabric, cut:
4- 10" x 18" rectangle
1- 30" x 30" square

From black fabric, cut:
4- 10" x 18" rectangle
1 – 30" x 30" square
1- 9" x 9" square (eyes, nose, mouth)

From green fabric, cut:
2 – 5" x 9" square for leaves


  1. Using pumpkin template, trace and cut 4 shapes from InnerFuse.
  2. Draw or trace Jack-O-Lantern eyes, nose and mouth, then cut shapes from InnerFuse. . Download pattern
  3. Using pattern, trace and cut leaves from InnerFuse. Download pattern
  4. Cut 7” square of Innerfuse.
  5. Referring to package directions, fuse orange fabric to one side of each pumpkin template shapes. Trim excess fabric around edges.
  6. Turn orange templates over and fuse black fabric. Again, trim excess fabric.
  7. Fuse green fabric to leaf shapes, trim, turn, and repeat on opposite side again using green fabric.
  8. Fuse black fabric to only one side of InnerFuse eyes, mouth and nose. Trim each shape. * Because these pieces are small, it is easier to fuse fabric then cut out shapes.
  9. Using any left over fabric, fuse to InnerFuse 7” square. This is the lid base and any fused fabric will not show on finished project.

    • Tip- Use a coordinating color permanent marker and mark the edges of the templates to hid the white of the InnerFuse after it is satin-stitched.
  10. Set sewing machine for a wide zigzag with a short length. This will be a satin stitch set-up. Insert a new size 90/14 ball point needle for best results. Test by sewing on a sample of InnerFuse covered with scrap fabric. Make any machine adjustments and record settings for future projects.
  11. Butt the edges of one pumpkin piece to another making sure they are aligned evenly with orange fabric facing up. You can use tape to temporarily secure them if necessary. Starting at the straight end of each template, satin stitch together, ending at tapered end. Continue stitching each pumpkin section joining the first to the last to complete. Because of the shape created by stitching the tapered pieces, the pumpkin is wrong side out when completed.
  12. Turn to right side. Gently shape the pumpkin and flatten the bottom to create a Jack-O-Lantern.
  13. Satin stitch around eyes, nose, and mouth pieces to finish raw edges. Hot glue each piece to the pumpkin to create a face.
  14. Satin stitch around InnerFuse leaves. Use a narrow satin stitch to create veins in each leaf.

Jack-O-Lantern Lid

  1. Trim each 30” x 30” black and orange fabrics with pinking shears for a decorative edge.
  2. Align fabric with wrong sides together and black fabric facing up. Center the 7” square InnerFuse piece and enclose square by gathering fabric into center. Work with fabric until it is evenly gathered and bottom of square is smooth.
  3. Wrap wire around gathered fabric as close to base as possible. Wrap wire several times to secure. Trim wire, leaving a 12” tail.
  4. Using awl, make a small hole in the bottom of each leaf as indicated on the pattern. Thread leaves through wire tail and place where desired. Wrap the wire tails around the permanent marker to create a decorative coil. Stretch coil to create pumpkin vine.
  5. Trim top of gathered fabric to create the look of a stem and also to create a handle for the lid. Add a raffia bow around base of stem for a completed project.

Fill with lots of treats for all your little goblins!