3D puff digitizing

What 3D puff is

3D puff is embroidery sewn over a layer of foam. Satin columns wrap the foam and cut through it at the edges, and the leftover foam is torn away, leaving raised letters or shapes. It is most common on structured caps, where the stiff front holds the shape.

How a puff file differs from a flat cap file

• Wide, dense satins. Columns need to be wide enough to cover the foam and dense enough to cut it cleanly.
• Capped ends. Open column ends let foam poke out. Puff files close the ends so the foam stays covered.
• Little or no fill under the foam. Underlay is kept light so the letter stays raised instead of flattened.
• Simple shapes. Thin serifs, small counters, and fine detail do not puff well. Bold block letters and simple marks do.

Not every design suits puff. If yours does not, we will say so and suggest a flat cap file instead, or a mix of puff and flat.

Price

3D puff: quoted per design. Letter height, cap style, foam thickness, and how much of the design is raised all change the work, so we confirm a price after seeing the art and before we start. See the rest of the menu.

What to send

• Artwork
• Cap style (structured is best for puff)
• Letter height and finished width
• Foam thickness, if you already have foam on hand
• Machine format

Ask for a puff quote