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Embroidery digitizing

3D puff digitizing

Puff is a foam problem before it is a stitch problem. The satin has to be dense enough to cut the foam cleanly, and every open end has to be sealed, or you get white fuzz along the edges.

Send artwork for thisSee all pricing
Quotequoted from the artwork
6 - 12 hoursUsual turnaround
12Formats included
UnlimitedRevisions

The edge is everything

Puff works by sewing over a sheet of 2mm or 3mm EVA foam and letting the needle perforate it so the excess tears away. If the satin column is too light, or the stitch angle runs parallel to the edge, the foam does not perforate and you end up picking white crumbs out of the letters with tweezers. We run the density heavier than a flat satin and set the angle so the needle crosses the boundary rather than following it.

Sealing the ends

Every open end of a puff element needs a cap: a short, tight run across the end of the column that closes it off. Miss one and the foam shows at the tip of an "A" or the terminal of an "S". We put them in on every element, and on letters with thin joins we tighten the join so the foam does not bulge out the side.

What does not work in puff

Small text, fine serifs, thin outlines and anything with a lot of interior detail. If your logo has 6mm text sitting under a bold wordmark, the honest answer is to puff the wordmark and run the text flat underneath. You get that split as a proof rather than a puffed mess you discover on the machine.

What lands in your inbox

The stitch file in whichever formats you asked for, a printable worksheet with the colour sequence and stitch count, and a flat preview image you can forward to your client. Ask for the editable source and you get that too, at no extra cost — it is your design.

  • EMB
  • DST
  • PES
  • JEF
  • EXP
  • VP3
  • HUS
  • XXX
  • CND
3D puff embroidery on a cap
Foam thickness planned for
2mm or 3mm, tell us which
Minimum column width
4mm
Ends sealed
Every open element
Flat fallback
Supplied alongside, free

Figures above are typical, not promises — the design decides. You get the actual numbers in the quote before any work starts.

Also punched here

Other positions.

ZB Punch left chest logo digitized on screen and stitched on a polo

Left chest

The bread-and-butter job. Polos, oxfords, fleece, softshells.

from $74 - 8 hours
Cap logo embroidery digitizing

Cap logo

Structured fronts, six-panel seams, cap-driver ready.

from $84 - 8 hours
Jacket back embroidery digitizing

Jacket back

Big panels, big stitch counts, and pull you have to plan for.

from $1512 - 24 hours
Sleeve logo embroidery digitizing

Sleeve

Narrow, curved, and hooped on an awkward frame.

from $74 - 8 hours

Next step

Need a 3d puff file?

Attach the artwork, tell us the finished width, the fabric and the format your machine reads. You will have a price and a delivery time back shortly.

Get a quote

Or email info@zbpunch.com

The small print

Last updated August 2026

ZB Punch is a digitizing studio. These terms cover the work we do for you — the files, the money, the deadlines and who owns what when the job is done.

  1. Who these terms are between

    "We", "us" and "the studio" mean ZB Punch. "You" means the business or person sending us artwork. Placing an order — by the contact form, by email or over WhatsApp — means you accept what is written here.

    We work business to business, mostly with decorators, uniform suppliers, promotional printers and agencies. Nothing here removes a right you have under the consumer law of your own country.

  2. What we deliver

    Embroidery digitizing: a hand-punched stitch file for the size, fabric and machine you tell us about, in the formats you ask for. Vector art: your logo redrawn as clean, scalable paths — drawn by hand, not auto-traced.

    A stitch file is made for one size and one fabric. Sewing it much larger or smaller, or on a very different material, will not give the same result. Tell us the intended size and garment and the file is built for it.

  3. Artwork you send us

    You confirm that you own the artwork you send, or that you have permission from whoever does. We do not check trademarks or copyright on your behalf.

    If a claim is ever made against us because artwork you supplied was not yours to use, that claim sits with you and not with the studio.

  4. Quotes and prices

    Prices on the site are starting points. A firm price comes back once we have seen the artwork, because the stitch count, the detail and the size all move it.

    All prices are quoted in US dollars unless we agree otherwise in writing. Bank charges and currency conversion at your end are yours to cover.

  5. Turnaround

    Most files go back within four to eight studio hours; larger or more complex jobs take longer and we say so before starting. Studio hours are Monday to Saturday, 9am to 6pm Pacific Time (US).

    Turnaround is a target we work hard to hold, not a guarantee. If you have a fixed deadline, tell us at the point of ordering and we will confirm whether it fits before we begin.

  6. Revisions

    Edits to the file we delivered — pull compensation, density, underlay, a stitch direction, a size tweak — are free, for as long as the job is open.

    A different logo, a new element, or a change to the artwork after we have punched it is new work and is quoted as such.

  7. Sew-outs and testing

    Always run a test sew-out on the actual fabric before a production run. Machines, hoops, backings, threads and tensions differ from workshop to workshop and only a real sew-out proves the file on yours.

    If the test shows something wrong with the file, send us a photo of the sew-out and we correct it at no charge. We cannot be responsible for garments spoiled by running a file into production without testing it first.

  8. Payment

    Unless a credit arrangement has been agreed in writing, invoices are payable on receipt. Regular clients are invoiced on the cycle we agree between us.

    We may hold delivery of new files while an invoice is overdue.

  9. Ownership of the finished files

    Once the work is paid for, the stitch files and vector files are yours. You may use them, edit them, archive them and sew them as often as you like, with no per-run fee and no licence to renew.

    We keep a copy of your files so a reorder or a resize is quick. Ask us and we delete them.

  10. Confidentiality and white label

    Your artwork, your clients and your prices stay with the studio. We do not sell, share or pass your files to anyone else.

    We work white label. Nothing of ours appears on what you send to your own customer, and we will not show your work publicly without your written say-so. We are happy to sign your NDA.

  11. Refunds

    If a file cannot be made to sew correctly for the size and fabric it was ordered for, we refund what you paid for that file.

    We do not refund a job that has already been corrected to your satisfaction, or losses beyond the price of the file itself — production time, garments, thread or downstream costs. Our liability for any order is limited to what you paid us for it.

  12. Cancelling

    Cancel before we start and there is nothing to pay. Once punching is under way, the work done up to that point is chargeable.

  13. Changes to these terms

    We update these terms from time to time. The version on this page at the moment you place an order is the one that applies to that order.

  14. Governing law

    These terms are governed by the laws of Pakistan, and the courts of Karachi have jurisdiction over any dispute arising from them.

Anything here you would like clarified before ordering? Ask us — a plain answer is faster than a clause.

ZB Punch – Embroidery Digitizing & Vector Art