3D Puff Cap Embroidery

The Challenge

Curved cap fronts distort flat digitizing files, and puff foam adds height that standard fill settings don't account for.

The Solution

We digitized directly against a cap-shaped hooping template and adjusted push/pull compensation for the foam layer so the letters stay legible after the foam is trimmed.

Deliverables

• 3D puff stitch file
• Sew-out sample