What is Cap & 3D Puff Digitizing?

Cap & 3D Puff Digitizing is the process of converting a logo or design into a machine-readable embroidery file that’s optimized specifically for caps and hats — including raised, 3D “puff” embroidery.
ensures your design stitches properly on curved hat surfaces like structured caps, snapbacks, or trucker hats.

creates a raised, foam-stitched effect by using special techniques like satin stitches, dense underlay, and spacing to allow embroidery thread to form around puff foam.

In short: this is not your average digitizing — it's tailored for the shape, tension, and structure of headwear, especially with raised, bold embroidery.

Why Is It Important?

  • Hats Are Curved

    Cap embroidery requires unique stitch paths to compensate for the curvature of the cap. A file digitized for flat fabric may distort on a hat.

  • 3D Puff Needs Precision

    3D puff embroidery uses foam under the design to create height. If the digitizing isn’t set up correctly (wrong stitch density or poor underlay), the result looks messy or collapses.

  • Clean Edges Matter

    On hats, especially with bold logos or lettering, jagged edges or thread breaks are easily noticeable. High-quality digitizing ensures clean outlines, smooth corners, and consistent thickness.

  • It Saves Time & Thread

    Proper digitizing = fewer thread breaks, faster production, and less trial-and-error at the machine. That’s money saved.

How Does Cap & 3D Puff Digitizing Work?

  • Artwork SubmissionYou send your design (JPG, PNG, PDF, or vector).Specify file format (DST, PES, EMB, etc.)Choose the type: Flat Cap Digitizing or 3D Puff

  • Digitizing SetupOur digitizers analyze the design for stitching on curved surfaces.For 3D puff: satin stitch settings are adjusted with:Looser densityCap-specific underlayNo fill stitch overlap

  • Machine File OutputYou receive a digitized file, preview image, stitch count, and thread color breakdown.Compatible with major machines: Tajima, Brother, Ricoma, etc.

  • Embroidery ProductionHoop your cap properly.Place puff foam if needed.Run the file, and enjoy clean, bold embroidery that pops.