Reuse-It Edmonton: Fused Plastic Bag Tutorial

Despite an unreasonably large stash of reusable fabric shopping bags, I somehow continue to collect plastic disposable bags. We recently blogged about 10 Disposables to Toss From Your Kitchen, so I am taking a renewed look at my waste and making a better effort to reduce my consumption. Meanwhile, I am experimenting with what to do with this collection of plastic bags.

Pinterest is a haven for creative repurposing ideas. Fusing several pieces of plastic together with an iron has been pinned in my account several times over. It was finally time to find out for myself if those crafty pinners are leading me down a path of melted messiness or fashionable eco-consciousness. Therefore, I tried making my own fused plastic bag!

I started by cutting off the seams of several plastic bags and laying each piece flat.

My plastic bags were all different sizes, colours and store brands.
Photo: Ellen Hanna

I opted to hide any logos or writing by keeping the plain side facing out.
Photo: Ellen Hanna

I matched the various sizes until I had a stack of 8 layers. I placed a towel on the table for protection and a piece of parchment paper on the very top to protect the iron. Then, I pressed firmly until the layers were fused, but not melted away. My iron doesn't have specific temperature settings (or even helpful fabric icons to guide me) but I found the mid-temperature was best. The plastic shrinks considerably, so don't be alarmed!

I needed five pieces to create one bag: two sides, a front, a back and a bottom.
Photo: Ellen Hanna

I repeated this process several times until I had five pieces of fused plastic sheets. At this point, I decided on measurements for my bag based on the largest size of sheet available.

I decided on the sizing based on measurements after my iron shrunk the fused bags.
Photo: Ellen Hanna

Using a rotary cutter and a quilting square, I cut the pieces down to their final sizes.

Pieces of the bag, ready to be sewn.
Photo: Ellen Hanna

Then for the fun part! I used a colourful thread to sew the edges together. I don't think this material would lend well to being flipped inside out, so I opted for a visible stitch. I used the widest zig zag stitch, fairly tight. I held the stitch as close to the outer edge as possible.

Visible stitching with red thread. Photo: Ellen Hanna

Next, I pinned two pieces together, right sides facing out and sewed a zig zag stitch straight down. I sewed this on all four edges until the walls of the bag were created.

The form of the bag beginning to take shape.
Photo: Ellen Hanna

The next step was a bit tricky, so I had to make sure to line things up carefully and use pins! I placed the bottom piece in place, then pinched the edges together in place, while using pins to secure. I picked a spot and started sewing a continuous zig zag stitch around the entire bottom. I was careful to backstitch in the corners to reinforce the bottom of the bag.

The material is stiff; therefore, lots of pins are needed to keep the bag in place.
Photo: Ellen Hanna

Stitching around the entire bottom of the bag, backstitching to reinforce in tricky places.
Photo: Ellen Hanna

The last step was sewing on handles to be able to carry the bag. I decided on using fabric scraps instead of fused plastic for a more comfortable feel. I used a visible stitching for the handle which was similar to the bag. I simply folded a long scrap piece, ironed well and then zig zag stitched down the middle to hold in place.

Simple fabric handles.
Photo: Ellen Hanna

For a more polished look, another option is to stitch a straight stitch down a folded piece to create a tube, then flip the tube inside out to make a strap without a giant zig zag stitch visible in the middle. However, I worked towards a "shabby chic" look and didn't mind the stitching showing or the rough edges on the inside.

Fabric handles sewn to the inside of the bag.
Photo: Ellen Hanna

I made this in haste while my brother was visiting with his family. It was meant as a gift and I wanted to give it to them before they flew home. As it turns out, they have been using it as a diaper bag non-stop for the past 4 months. It has been dragged around everywhere, while being emptied and filled endlessly. It is still in great condition; therefore, this bag made with fused plastic bags is a real winner for strength!