3D puff embroidery on fitted and snapback caps
3D puff is embroidery stitched over a layer of foam so the design stands off the cap. It is the look most team, streetwear and bar caps want on the front. Battle Born Clothing runs puff on two commercial embroidery heads and quotes it per design.
What puffs well
- Block letters and numbers at least about 0.4 in tall
- Simple solid shapes: shields, circles, a single icon
- Monograms and short wordmarks (one to five characters)
- The main shape of a logo, with the fine detail stitched flat around it
What should stay flat
- Thin lines, script with hairline strokes, small text under about 0.25 in
- Gradients and photo-style art
- Logos with many small separate parts
- Anything on an unstructured or thin performance crown
Blanks that take puff
Puff needs a structured front panel with buckram. Good: Flexfit 6277, 6210, 6297F, 110F, YP 6089M, Richardson 511 and 112, Zapped Cobra. Fine on the New Era NE1000 and NE400. Avoid on lightweight shells like the 6100NU for large puff areas.
How we price it
Flat embroidery is on the tier table, $7.00 per cap at 24-47 and $5.00 at 144+. Puff is quoted per design because foam area and the dense satin columns that cover it drive stitch count. When you send art we quote puff and flat side by side. One $18.99 digitizing fee covers a puff + flat combo.
Artwork for puff
Send vector art if you have it. We will tell you on the proof which parts we puffed and which we flattened, and why. See the artwork guide for puff.
Questions
Does 3D puff cost more than flat embroidery?
Usually yes, because the foam is covered by dense satin stitching and the stitch count rises. We quote it per design so you see the exact difference.
Can you puff a logo with small text?
We puff the main shape and stitch the small text flat. Puffing text under about 0.25 in tall loses legibility.
Will the puff flatten in the wash?
Puff foam is heat-sealed by the stitching and holds up to normal wear and hand washing. Do not put a puff cap through a hot dryer.