Looking to spice up your next embroidery project? If you’re up to the challenge, give foam embroidery a try! Foam embroidery (also known as 3D puff embroidery) is a great way to add dimension to your designs and impress your friends, customers and even yourself. Following these easy steps, you can unlock the world of foam!

If you’re new to digitizing, you may be wondering what exactly is foam embroidery? Foam embroidery is simply where your design art or lettering is puffed above your stitching, giving it a 3D effect and feel. It may seem intimidating but remember to have fun with it! Embroidery is an art form and like anything practice makes perfect.

Note: 3D puffy foam embroidery should only be incorporated with designs that have been digitized specifically for the foam process.

Step 1: Run the Regular Embroidered Elements

With “foam” designs you need to run the regular embroidered elements first, all Embroidery Legacy designs are created with this in mind.

3d foam embroidery tutorial

Step 2: Stop the Machine

Once all regular embroidery colors are completed your color information sheet will give you a suggested thread color and say the word “foam” after it. When reaching this color change, the design should move to the top of the design and you should stop your machine.

3d foam embroidery step by step

Step 3: Lay the Foam

At this point you will lay the foam down within the areas to be embroidered. (Always try to use the same color thread and foam whenever possible).

laying down 3d foam embroidery

Step 4: Sew the Tack-Down Stitches

The first stitches to be placed down are “tack-down” stitches to secure the foam to the fabric.

Step 5: Continue Sewing

Then the design will proceed to finish all the areas to be done in foam.

stitching 3d foam embroidery

Step 6: Remove the Foam

Now your ready to pull the foam off, it should tear away easily with designs that have been digitized properly.

removing 3d foam embroidery

Step 7: Smile!

You now know how to do “foam”.

finished 3d foam embroidery

Hopefully this has helped you better understand a bit more about foam embroidery designs, remember to have fun learning this new embroidery technique, if you haven’t already go try stitching out your own foam-design!

Want to see how far you can take foam? Watch this awesome video of a 3 layer foam bulldog cap created by John Deer now:

Let me know if this tutorial helped or if you have any questions below!

P.S. Want to try stitching four of our embroidery designs for free? Click here to download our Free Embroidery Legacy Design Kit today!