Custom 3D Puff Patches with Raised Foam Lettering

A 3D puff patch is embroidery stitched over a layer of foam, so the lettering stands up off the surface instead of lying flat on it. This page sells the patch itself, made separately and then attached to the garment you choose. That is a different product from puff stitched directly onto a finished cap, and the two are ordered in different ways.

Foam supports weight, not detail. The stitching has to fully enclose the foam so no part of it shows at the edges, which means letters and shapes need real thickness in them. Around 10 mm is the working minimum letter height, and the standard raise is 3 mm with a range from 2 mm up to 6 mm depending on the design. A thin script or a small serif will not hold, because there is nothing for the foam to sit inside.

Most good pieces are not entirely puff. The bold element is raised and everything that needs definition, an outline, small type, a date, is stitched flat alongside it. That combination is a normal build rather than an upgrade, and it is what people are usually picturing when they describe a cap they have seen. Send the artwork and the finished size, and the proof will show which elements are raised, which are flat and how high the raise sits.