3D puff embroidery digitizing for caps and apparel

3D puff embroidery, also called foam embroidery, stitches a cover of satin over a layer of foam so lettering and shapes stand up from the fabric. It needs a different file from flat embroidery: tighter density, a specific stitch direction and settings that perforate the foam so it tears away cleanly. We digitize puff files with those settings built in.

Upload artwork

Red and black spartan mascot with a round shield reading EC, embroidered

What you get

  • Foam-specific density

    Dense satin covers the foam fully and cuts it so the extra pulls away clean.

  • Simplified detail

    Very thin strokes do not hold foam well. We simplify them so the finished piece looks sharp, not messy.

  • Mixed flat and puff

    Keep the logo flat and puff only the lettering, or the reverse. We set up both in one file.

  • Cap ready

    Designs are sequenced and sized for the front panel of structured caps.

Quick facts

Best forBold shapes and thick lettering
AvoidHairline strokes and tiny text
Common size2 inches tall on caps
TurnaroundMost designs are returned within 12 to 24 hours
DeliveryBy email, anywhere in the USA

Best for

  • Cap and hat decorators
  • Streetwear and team brands
  • Bold block lettering and simple icons
  • Merch that needs to stand out

How to order 3d puff embroidery digitizing

  1. Upload your artwork

    Take a photo or choose a file. A phone photo is enough to get a quote.

  2. Add size, placement and fabric

    These details decide how the design is built.

  3. Approve the quote

    We email a price before work starts.

  4. Receive your files

    Stitch file, preview and thread sheet by email.

Get a free quote

Free quote. We reply by email before any work starts.

1 Add your artwork

    JPG, PNG, HEIC, PDF, AI, EPS, SVG, PSD or CDR. Up to 6 files.

    2 Tell us about the job

    Optional Leave the height empty and we keep your artwork proportional.

    3 Where should we send the quote?

    Disclaimer: Please perform a sample sew-out of this design on a scrap piece of fabric before proceeding to final production. We are not responsible for any garment or material damage caused by failing to test the digitized file beforehand.

    Your files are used only to prepare your quote and order. See our privacy policy.

    Patch Digitizing questions

    Do you make the physical patches?

    No. We create the digitized stitch file and vector art you need to produce patches on your own machines or with your supplier.

    What border style do you digitize?

    Satin borders sized for your edge. Tell us your border width in the notes.

    Can you digitize a patch from a small logo?

    Yes. We often redraw the logo as vector art first so the stitch file follows clean edges.

    Can patches include 3D puff?

    Yes. Raised lettering can be added to a patch design.

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