Welcome to another inspiring episode from the School of Stitched Textiles Podcast – Textile Talk! In this conversation, host Gail Cowley is joined by Karen Miller, a passionate educator, quilter, and dedicated representative of Aurifil Threads. If you’ve ever stitched with Aurifil and wondered what makes it so smooth, so strong, and so satisfying to use, you’re going to love this behind-the-scenes look into the fascinating world of thread production.
Karen lifts the lid on how Aurifil threads are made—revealing a surprising amount of science, craftsmanship, and tradition that goes into every spool. From fibre sourcing in Egypt to singeing with naked flames in Italy, this episode will make you see your threads in a completely new light. Whether you’re a seasoned stitcher or just getting started, there’s something for every maker in this rich and engaging discussion.
Textile Talk with Karen L Miller
Listen to the episode on your favourite podcast platform or click the link below to listen now.
Behind the Thread with Karen Miller of Aurifil
In this episode, you’ll follow the journey of Aurifil thread from cotton field to finished spool. Karen explains how the cotton is grown in the Mako region of Egypt, where the conditions are perfect for producing extra-long staple fibres. These fibres form the foundation for Aurifil’s reputation for strength, durability, and softness.
You’ll discover the multi-step production process that ensures each thread is perfectly balanced and ready for stitching. Karen talks us through everything from spinning and twisting to reeling, dyeing, and even a process known as thermo fastening. Every step has a purpose, and each contributes to the unique quality that makes Aurifil such a favourite among textile artists and quilters.
One of the most fascinating parts of the episode is hearing how the threads are passed through a paraffin oil bath. This step isn’t about adding visible shine or slickness—it’s a subtle finishing process that reduces friction and lint, helping the thread glide smoothly through sewing machines and hand needles alike. Karen also shares details about the singeing process, where the threads are passed by a flame to remove fluff and loose fibres, ensuring a cleaner, stronger finish.
If you’ve ever wondered why thread weight and ply matter, Karen offers a really clear explanation of what those numbers mean and how they affect your work. She also explains why twists per inch are so important, and how Aurifil ensures their threads don’t fray, split, or twist back on themselves while you work.
Why Thread Quality Matters
Listening to Karen describe the intricacies of thread production is a great reminder that materials matter. We often focus on fabric, tools, or technique, but thread plays such a crucial role in the success of a project. A well-made thread can prevent machine issues, reduce lint build-up, and make your stitches look cleaner and more precise.
This episode is full of those little “aha” moments where the science of threadmaking suddenly clicks. You’ll come away with a deeper appreciation for the threads in your kit and a better understanding of why choosing the right thread can make all the difference.
Connecting Tradition and Innovation
Karen and Gail also explore how some of Aurifil’s modern processes connect with traditional handwork practices. There’s a lovely moment of reflection on how hand embroiderers have long used beeswax to coat their threads—similar in principle to Aurifil’s paraffin oil bath. This gentle coating technique, whether ancient or modern, helps the thread move smoothly and last longer.
The episode makes it clear that Aurifil’s success isn’t just down to innovation. It’s also rooted in respect for tradition and a deep understanding of how stitchers use thread in the real world.
Tune in and Get Inspired
This is a truly fascinating episode that combines technical detail with creative inspiration. Karen’s enthusiasm is infectious, and her knowledge will leave you looking at your thread stash with fresh eyes. Whether you’re a hand stitcher, a machine quilter, or someone who just loves learning how things are made, this episode is full of practical insights and inspiring takeaways.
So, grab a cuppa, settle in, and let Karen take you behind the thread. You’ll never see a spool of thread the same way again.
🎧 Listen to the full episode now on Spotify, Apple Podcasts, or wherever you get your podcasts.
