Decorating Solutions: Create 3-D Embroidery - Five Steps

Give a logo extra dimension and interest with puff embroidery. Embroidery expert Drew Coufal of Ohio-based Sew & Sew Embroidery shares his tips for turning a regular logo 3-D.

1. Review your artwork.

Thicker text and/or wider elements within a logo will puff up best, so choose these areas to do as the puff application. Note: Not all logos are good candidates for puff imprints.

2. When punching, set up puff elements as a new area.

The density within the puff areas will be double a normal density setting. Avoid underlays that can flatten the foam down and cap any end points (open ends) of the puff elements that could cause foam to squeeze out of the stitching. For example, on the letter “L” cap, the top and bottom of the letter are areas that would cause the foam to squeeze out from under stitching.

3. Program a stop code in the logo file.

This can also be programmed at your machine to stop the run, allowing your operator to place foam onto the garment.

4. Match the foam color to your puff thread.

This will cover any small foam particles that will show after stitching. Tip: If tiny foam particles do show, use a steamer to shrink the foam. If large particles show, your setup may need further modification to properly cover the foam and perforate the foam material as it sews. Loosen your thread tensions so it doesn’t pull too taut and compact the foam.

5. Sew the logo’s foam elements last. 

Tip: Your machine operator can remove the garment from the machine and reload a new pass while your finishing department pulls the foam and cleans stitches, backing and more.