1.
With the right side facing up, place the 4.5" square on top of the
scrap 4" square. Align the top right two edges. Use a scant 1/4"
seam (a seam that's just a smidge smaller than a regular 1/4" seam) and
start sewing along the right edge.
2.
After a few stitches, take the bottom right corner of the top square and
align it with the bottom right corner of the bottom square. Gather the fabric
to the middle of the square and using two finger, pinch the fabric to create a
pleat. Hold or pin the pleat down as you sew over it.
3.
When you get about a 1/4" to the edge of the square, stop with your
needle down and pivot so that you sew down the perpendicular edge.
4.
Repeat Step 2 to create a pleat, and do the same for the third side.
5.
Leave the 4th side open. You will stuff the puff and close that up a
little later.
6.
Work out a pattern design on paper and pin the squares to your desired
pattern and colors.
7.
Chain piece each square instead of sewing every block separately.