In my day, Girl Scout badges were 1 1/2" rounds. You can make your any shape you want. Try hearts or stars or a free-form shape.
Select a 100% cotton or linen fabric in a color of your choice. I've chosen pale purple. A fat quarter will give you many badge blanks. Iron the fabric and a piece of cotton muslin, Unique Tear-Away stabilizer, or your favorite non-fusable interfacing. Pin the two layers together with your colored fabric on top. Using a pencil, draw a bunch of shapes on the fabric. Using a tight satin stitch, stitch a 1/8" border around all of the circles. Leave the badges attached to the piece of cloth until you have embroidered your design, which you can do by hand or machine. You can also bead it or anything that comes to mind. Once you've finished the badge, trim it close to the satin stitching with a pair of sharp scissors and seal the edges with Fray-Check.
Click here to return to the main merit badge page.