Pick a random dude to base how your puppet will look like. Think about what the puppet's characteristics are. Will it have a long or short face, big or small nose, round or other shape nose, big eyes, small eyes... Should it be fuzzy, furry, or just soft and cuddly. Will you have a bald puppet or something with a unique hairdo? What accessories will it need. Or, just start sewing and create something as you go...
Step 1: Create the mouthpiece...
You can also use a serger to do most everything except adding details where you need a straight or zigzag stitch. You can look at the Robohoodie for American Girl Dolls for more info on using a serger.
This project does not require any expensive foam pieces or core shapes. You do not need to deal with toxic foam bits from cutting and sanding or need to use toxic glues.
All you need is:
- fabric material of any kind
- a bit of cardboard
- a sewing machine
- a serger if you have one
- an imagination
I folded over that sheet of black felt to make the top and bottom of the mouth. Add a piece of red felt shaped like a tongue.
Cut out matching pieces of some other material to match. This is to form 2 pockets for the top and bottom of the mouth. Later on we will slip in cardboard stiffeners and that is where you place your hands to animate the mouth. I serged the edge of fabric for the pocket opening.
Sandwich everything and serge around the half-moon shape. Cut out carboard stiffeners to fit in the pockets. Test fit and take out to make the rest of the sewing easier.