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I love folded star ornaments, I try to make one a year.  Here's how I make mine. I wrote these instructions back in 2008 and posted them in a 3 part series.  I decided to bring them all together in one posting for a repeat posting.. One year I am going to try and use glue instead of pin or I'd love to find shorter pins.  Enjoy!
I start out with a bunch of 2.5" blocks.  When I first wrote these instructions, I created 2.5" strips and then cut into 2.5" blocks.  Now, you could probably cut out a ton of 2.5" blocks with a die cutter if you have one.
After
 the squares are now in 2.5" blocks, it's time for the ironing. But 
first, set aside 2 blocks from each color that you will not be ironing.
- Step 1 - fold the 2.5" block in half. Use your spray starch if need to make it flat.
 
- Step 2 - fold the folded half block again into a square. Use your spray starch again if needed.
 

The
 order in which you prepare all of your blocks is up to you. Meaning, do
 you do a completely iron and fold one block completely and then move on
 to the next one? Or, do you iron all in half first before you move on 
to the next step. Up to you.
Once you have your tiny twice folded 
square, you now open it back up to the original half size and then we 
fold the edges in to meet the center fold line. Think back to when you 
made your paper hats. You bring the right side into the center fold line
 and press and then you bring the left side into the center line and 
press. Or, you fold them both in, hold them with your finger or tweezers
 and then press at once. Be careful not to burn your finger like I 
usually end up doing :-) You will end up with mini triangles. 

Be
 precise when lining up the sides to the center, the closer (without 
overlapping) the better. Here I am holding one block before I iron it 
down. I would spray starch here to make sure it stays.

From
 here, it's just repeat, repeat, repeat until you have a pile of 
triangles such as this. Notice my saved blocks that have not been 
ironed.
Now it's time to begin pinning the triangle pieces to 
the star. Keep in mind there are no "must follow rules" they are all 
left up to your individuality and how you would like to arrange the 
layers. Also, things won't match up perfectly. That's OK, slap on another layer and cover up the imperfection :-). Most of all, make it your own. 
Place
 two of the unfolded squares evenly spaced apart on the foam. Pin each 
corner and have the corners meet from each side evenly spaced apart.
Layer 1 Step 1 - Place your first triangle directly on the flat 2.5" square just placed. Match the wide edge of the triangle with the corners of the squares.
 Pin the corners first and then the point. Remember, place the pin in 
the point in between the two folds a little below the edge. Then pull 
the folded flaps up and over to hide the point pin. 
Layer 1 Step 2 - Complete the second triangle directly across from the first one placed, same method.

 Layer 1 Step 3 - Place the 3rd triangle in the empty space besides the two just placed, match points.

 Layer 1 Step 4 - Place the last triangle to finish the square. All points should match up.

 Next layer, decide how large you want your center star. You should be 
able to fit 3 or 4 layers without using half the foam ball's space.
Layer
 2 Step 1 - When you decide where you would like to start layer two, 
place in the point pin first and then pin down the outer corners of the 
triangle.

 Layer 2 Step 2 - Place the second piece completely opposite of Layer 2 Step 1. Pin center, hide pin, pin corners of triangle.
Layer
 2 Step 3 - Place the third piece 90 degrees from pieces 1 and 2 from 
layer 2. Pin center, hide pin, pin corners of triangle.
Layer 2 Step 4 - Place the 4th piece directly opposite of piece 3. Pin center, hide pin, pin corners of triangle.

 Layer 2 Step 5 - Now add a 5
th
 triangle to the areas not covered by the 4 pieces of layer 2. It's 
almost like another layer of the same color. You are now starting to 
form your star. Pin center, hide pin, pin corners of triangle.
Layer 2 Step 6 - Place the 6th piece completely opposite of Layer 2 Step 5. Pin center, hide pin, pin corners of triangle.
Layer 2 Step 7 - Place the 7th piece 90 degrees from pieces 5 and 6 from layer 2. Pin center, hide pin, pin corners of triangle.
Layer
 2 Step 8 - Place the 8th piece directly opposite of piece 7. Pin 
center, hide pin, pin corners of triangle. You should see your first 
star.
Layer 3 - next color
Layer
 3 Step 1 - When you decide where you would like to start layer three, 
place in the point pin first and then pin down the outer corners of the 
triangle.

Layer 3 Step 2 - Place the second piece completely opposite of Layer 3 Step 1. Pin center, hide pin, pin corners of triangle.
Layer
 3 Step 3 - Place the third piece 90 degrees from pieces 1 and 2 from 
layer 3. Pin center, hide pin, pin corners of triangle.
Layer 3 Step 4 - Place the 4
th piece directly opposite of piece 3. Pin center, hide pin, pin corners of triangle.

Layer 3 Step 5 - Now add a 5
th
 triangle to the areas not covered by the 4 pieces of layer 3. It's 
almost like another layer of the same color. You are now starting to 
form your second star. Pin center, hide pin, pin corners of triangle.
Layer 3 Step 6 - Place the 6
th piece completely opposite of Layer 3 Step 5. Pin center, hide pin, pin corners of triangle.

Layer 3 Step 7 - Place the 7
th piece 90 degrees from pieces 5 and 6 from layer 3. Pin center, hide pin, pin corners of triangle.
Layer 3 Step 8 - Place the 8
th piece directly opposite of piece 7. Pin center, hide pin, pin corners of triangle. You should see your second star.

If
 you have room for another layer without going over the half way point 
of the foam ball, switch colors and repeat steps from Layer 3.
Once
 you are done with all your layers, I sometimes go back and pin down all
 the exposed outer edges in prep for the ribbon or fabric wrap that will
 hide all the pins.

When finished, flip over the ornament and repeat all steps. I like to use opposite center color and then build out.
 
Finishing Both Sides
I
 finished pinning on the second side of my folded star ornament. I 
decided on the second side I would only place 3 layers of fabric. 
However, I started the center in green this time. So, when I was 
finished, both sides met with the green fabric. Here are photos of both 
finished sides.
Where
 the sides meet is where you will place your fabric strip or ribbon. 
Most times, my sides don't match up perfectly. But like I referenced 
previously, who cares. It's going to be covered up with fabric anyway. I
 just make my fabric strip a little wider to make sure I cover it all. 
Here are my sides. See how at one spot, they overlap a little and in 
another, there's a nice gap. 
Finishing the Ornament
Wrap
 a string or measuring tape around your ornament to determine the size 
of ribbon or fabric you need. For this size foam ball, I'll need a 10" 
strip to be exact. However, I like to add a couple inches to that in 
case I have any issues and to make a tube at the top to act as a hanger.
 I usually use matching fabric (or contrasting, depends on the mood :-) 
2" wide strip. 
Then I fold the strip in 
half, right sides together and stitch a 1/4" seam down it to make an 
inside out tube. Turn the tube right side out and press with the seam on
 the inside, bottom center of the strip. I end up with a 3/4" finished 
strip to wrap around the ornament.
 
- Optional instructions
 - Just fold the sides in (1/4" each) to the back center and iron to 
make a 1.5" strip with sides folded under. Then, fold this in half again
 to form the 3/4" strip. This hides the raw edges and still gives you 
the 3/4" strip to wrap around the ornament.
 
I
 cut the finished strip to 10" (or however long you need) and then from 
the excess piece I cut a 1" piece which I'll use later. On the 10" 
strip, I add double stick tape. Then carefully thread the one end 
through the 1" piece and secure with tape on the underside. This will be
 the hanger at the top of the ornament. 

Place
 the area with the 1" piece on top of your ornament if you have a 
preferential "top". Wrap the piece around your ornament and secure. When
 you come to the top, feed the other end of the wrap into the 1" piece 
on the top of your ornament. I'll even reach in with a pin inside this 
piece and secure further. Now, your ornament is ready for hanging. 
- Optional instructions
 - just use the 10" strip and tape it to the ornament letting the ends 
meet at the top. Glue on a piece of fabric on top to cover the joint of 
the two ends where they meet at the top. Adhere something to hang the 
ornament.Here's the finished wrap. I like using fabric because the wrap 
is then very smooth. 
 

Hang on your tree or give as a gift! Please let me know if you have any questions.
Thanks for stopping by!
Thanks for stopping by!
 
~*~Trish~*~