Bold, Raised, Impossible To Miss

3D PUFF,
DONE RIGHT.

Foam-backed embroidery that lifts your design off the fabric, with sharply defined edges and a bold, sculpted profile. Explore the details below — up close, side by side, and everything in between — before you request your quote.

See It Up Close View Specs

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Foam Height

Thread Colors Available

Piece Minimum Order

Production Turnaround

Real Lift

A layer of foam sits under the stitching, giving your design a raised, sculpted profile that flat embroidery can't match.

Built To Last

The foam core is fully enclosed in stitching, so it holds its shape and resists flattening through years of wear.

Made To Be Seen

The raised, bold profile is built for letterman jackets, caps, and team gear — it reads at a glance, from across the room.

See It Up Close

Every Detail, Zoomed In

Front Detail — full patch — the complete patch, straight on

What You Approve Is What You Get

Proof vs. Finished Patch

Digital Proof Finished Patch

Construction

The Full Spec Sheet

Everything that goes into a standard 3D puff patch.

Base FabricTwill or felt

Foam HeightUp to 4mm raised

Thread TypePolyester, rayon on request

Edge FinishMerrowed or hot-cut

Backing OptionsIron-on, sew-on, velcro, adhesive

Max Colors12 thread colors per design

Size Range2" – 8"

Minimum Order25 pieces

From Art To Patch

How It's Made

Five steps, from your artwork to a finished, raised patch.

Artwork Review

We check your design for bold, simplified shapes that will hold their form once raised in foam.

Digitizing

Your art is converted into a stitch file, mapping exactly where the foam layer sits beneath the thread.

Thread Matching

Colors are matched to your brand palette and shown on a digital proof before production.

Foam & Stitching

Foam is cut to shape and stitched over on commercial multi-head machines, then trimmed and edge-sealed by hand.

Shipped To You

Packed flat in water-resistant sleeves and shipped with tracking, worldwide.

Inspiration Gallery

Reference Reel

What People Order

Straight From Customers

"The raised foam gave our team logo so much more presence on the letterman jackets than flat embroidery ever did."

— Casey L., High School Booster Club

"Ordered 500 puff patches for our varsity jackets. Every single one had crisp, even edges and held their shape."

— Morgan D., Athletics Department

"The digital proof caught a detail that would've gotten lost once puffed up — saved us from a costly reprint."

— Taylor R., Youth Sports League

"These patches have survived two seasons of practice gear washing and the foam still holds its lift."

— Jamie F., Equipment Manager

Questions

Before You Order

Can't find your answer here? Reach out — we're happy to help.

What's the minimum order quantity?

Just 25 pieces per design — there's no massive factory minimum standing between you and a custom patch.

How tall does the foam raise the design?

Standard foam height is up to 4mm, giving a noticeably raised, sculpted profile without becoming fragile or top-heavy.

Can 3D puff handle small text or fine detail?

3D puff works best with bold, simplified shapes and lettering — fine detail tends to lose definition once the foam is added. Our design team will flag anything too intricate and suggest a fix.

What's the difference between merrowed and hot-cut edges?

Merrowed edges have a stitched border wrapping the patch for reinforcement — the classic look. Hot-cut edges are heat-sealed instead, allowing for tighter, more intricate shapes.

Do you offer rush production?

Yes, rush production is available for an additional fee — just mention your deadline when requesting your quote.

I don't have finished artwork — can you still help?

Absolutely. Send us a rough sketch, a description, or a reference image, and our design team will build a proof from scratch.

3D PUFF, DONE RIGHT.