What is 3D Puff embroidery?</p>

Embroidery is a growing business and a lot of people are in search of information about the know-how of 3D puff embroidery or 3D foam embroidery. The sturdy designs on baseball caps are attained by the use of 3s embroidery foam and this is where the name of 3d puff embroidery came from. Increasing demand for 3D demands has been noticed over the years especially for caps and hats. It is used as the traditional embroidery to add textured appearance to your logo, with only difference that the added layer of foam gives a more dimensional depth into the logo. However, a lot goes into the making of a 3D puff embroidery.

Digitizing Technique for 3D Foam

The technique used for digitizing 3D foam is quite similar to the technique used for applique, with the only difference of cover stitch cutting the foam and thereby is mostly a high-density Satin stitch. Some important things to remember beforehand


  • Choose a suitable machine, run a few tests on different machines to find the one best suited for your desired optimum speed to give out the quality results.
  • Choose the right fabric, the stitch density is usually high in 3D puff embroidery so it is necessary to avoid choosing delicate and slippery fabrics. The fabric of caps is more stable than that of towels as their loft fades and the design looks far away to give a captivating look.
  • Sharpen your needles, in order to make it easy to remove the foam after it is highly recommended that sharp needles must be used for perforations.
  • The most important thing to remember is to choose the right foam as if the stuff is too stiff, it will be difficult to remove the excess after the embroidery. Along with keeping the color of foam in the head when choosing the color of foam is very crucial for the embroidery.

A guide for how to digitize 3D puff embroidery

  • Satin fill, choose satin fill as it has no stitches inside the object as the needle stitch cuts the foam every time of penetration so it is necessary that the foam should not push down the stitches with object and satin fill is the only that can do the job right.
  • The stitch space, use 1.7mm run stitch to tack the foam down.
  • Close the open ends, digitize a narrow column across the open ends so that it will help to cut the foam at the ends and to avoid from poking or lifting of the foam from the end cover stitches.
  • Lay the underlay, using zigzag with stitch spacing of 1.5 - 2.0mm lay an underlay to keep the foam down along with cutting and covering.
  • The satin cover density, it should be raised more than normal varying the thickness of the embroidery thread, height, and color of the foam used. With auto-spacing off the satin, density must be 0.2 - 0.4mm.
  • The pull compensation, according to the foam used must be raised to 0.3 - 0.5mm.
  • Tie-off sticthes, make sure to secure them.
  • After embroidering, gently pull the foam away from the embroidery design.


The process seems a lot hectic, widespread, and detailing, yet it is not. It can all easily be done with Genuis digitizing.