- Free proof before you pay
- 12–24 hour digitizing turnaround
- Free unlimited revisions
- Money-back quality guarantee
- Every format included — files are yours
- Free proof before you pay
- 12–24 hour digitizing turnaround
- Free unlimited revisions
- Money-back quality guarantee
- Every format included — files are yours
3D Puff Embroidery Digitizing
Puff embroidery stitches over a foam strip so the design stands off the cap. It looks superb when the file is built for foam, and unmistakably bad when it isn't — grey foam showing through the stitches, ragged ends, letters that blow out. A puff file is a different build, not a setting you toggle. Ours start at $7.
Columns sized for foam
Satin columns need extra width and density to wrap the foam and close cleanly. Standard column widths leave foam visible along the edges.
Sealed ends and corners
Every stroke end gets a locking treatment so the foam tears away clean instead of fraying out of the stitching.
The right elements chosen
Not everything should be puffed. We keep bold strokes raised and drop fine detail to flat stitching, which is what makes a puff design read.
Foam thickness accounted for
2mm and 3mm foam behave differently. Tell us which you run and the file is built for it.
How it works
Send the logo and foam spec
Finished width, cap or garment, and foam thickness if you know it. If not, we'll advise.
We rebuild it for puff
Puffed and flat areas separated, columns widened, ends sealed, travel paths kept off the foam.
Test and run
Stitch one before the batch. Revisions are free if the foam shows anywhere it shouldn't.