Working with 3D Puff Embroidery - Part 2
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Working with 3D Puff Embroidery - Part 2

Digitizing - Next steps when working with 3D Puff designs

Digitizing for 3D Puff Embroidery

Adding 3D puff embroidery to your design is a great way to make your logo stand out, but how is it digitized?

Foam is added to the design to create loft. Because of this, we need to digitize specifically for the foam areas. The 3D part is always last, so if you have flat areas in your design, you will need to do those first.

While this can vary, there are usually these steps:

  1. Flat embroidery
  2. Placement line for foam
  3. Puff area

In the picture below, the top color stop (outline) is flat embroidery.  The second stop is the placement line which will help the operator determine where to place the foam.  The third color stop is the 3D part of the design.

Run Order for Digitizing













Perforating the foam

Perforation around the perimeter


The foam needs to be perforated, similar to a postage stamp, to the shape desired. This is done by using a satin stitch that is twice as dense as regular flat embroidery. The needle points are what cuts the foam. The entire perimeter of the shape needs to be cut. Since satin stitches have open ends in the columns, you will need to create a cap. The outer edge of the satin stitch cap will help perforate the foam.

Like a stamp, the foam will need to be perforated around the perimeter of the puff area.






Top stitching

Top stitching will go over the caps. The final satin stitches will cover up the caps and other underlay. Making the stitches more dense is not all. We need to do something about the open areas (circled) or foam will be exposed as shown below.












Shown here, in the following image, are the caps, which will help cut the foam on the otherwise exposed areas, these are done before the top stitching and will not show.












On the left below, the hilted parts are known as “caps”. They help perforate the ends of the design that might otherwise let the foam peek through.  On the right, a design might have certain stress points that will also need stitches. Wherever there is a chance of stitches pulling apart, this underlay will prevent the foam from showing through.

Hilted capsStress points

Watch for our next installment in this 3D Puff series, when we go through the process of embroidering the puff design.



Author: Jesse Elliott

Over 30 years of experience in digitizing embroidery and screen printing

Previous Article Working with 3D Puff Embroidery - Part 1
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13 comments on article "Working with 3D Puff Embroidery - Part 2"

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I am in the process of buying a tajima tmark machine and plan on using it primarily for Raised logos on Ball caps.

Any info you can provide to make the process go smoothly will be greatly appreciated. The machine will be in the end of the month and I have 500 pieces to do.

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pizza tower

I appreciate the patience if you do it, to complete it takes a long time meticulously.

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You can find out more here than on other websites. Honest reviews will give you a solid understanding of which writing services you can trust.

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John Edwart

I've read your article. Honestly, I've never read this type of informative and efficient article before. This article will help lots of beginners like me to build skills in embroidery. Love to read your incoming blogs too. Really appreciate your work and dedication.

We have to fulfill your embroidery needs.

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smash karts

I wish I could create the best stitching. However, I'm just a newbie. I do not have enough experience. Your article offered many beneficial things.

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1Dollar Digitizing

Very helpful blog for the people who have interest in 3d puff embroidery step by step each step of 3D puff embroidery is explained outstandingly. I am running embroidery digitizing company, for further details please visit

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Drift Hunters

I love how the Drift Hunters game creates an exciting and exhilarating drift racing experience!

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I appreciate patience if you do it, it takes a long time to meticulously complete it.

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Working with 3D Puff Embroidery - Part 2

Working with 3D Puff Embroidery - Part 2

Jesse Elliot, our digitizing expert, shares his insights in this second installment on how to digitize 3D puff embroidery.