3-D Cap

[GameDayDesigns]

I know there has been discussion over 3-D puff foam on hats but...does anyone know how they do the hats that are sold at the mall? It is almost like cardboard under the stitches. Definitely not the 3mm foam I have used. These are very hard underneath the stitches and stick out quite a bit. The foam tends to get smashed down some when stitching and certainly not as hard and as high as these other hats. Any info would be greatly appreciated. Thanks!

[signman]

This was brought up before, I've seen them-mounted one for an award. Lettering was almost 1/4" high.
As far as I can tell, the front panel is embroidered 'flat', before the hat is actually assembled. Makes it much easier.
The bulk of your 'retail' logo'd hats are done as 'piece' goods-the faces are embroidered while just 'cut material'. You can spot this fast on hats with the designs running down to the brim-it continues under the edge of the brim-so you can see how it is done.

[GameDayDesigns]

Thanks Roland, I knew the ones that ran along the brim were done before construction but was hoping that the others had a way of being done post construction. Thanks again!

[Steve I]

When I do puff hats I usually use two layers of 2mm foam. Any stitching over the foam I use the standard setting for the actifeed and set it anywhere from 27-32, this allows enough thread as to not crush the foam and loose the effect. It took a lot of sew outs and tinkering to get the process fine tuned. I went to the mall and looked at caps to see how they were done, how they handled corners and which ends were capped and which were not. It helps to use foam as close as possible to the thread color. I found all colors at Michaels. I have also found that the foam with the adhesive back tears off cleaner than the foam without.


Steve I.
Trinity Embroidery

[GameDayDesigns]

Thanks Steve. I have not seen the foam with adhesive back so I will definitely have to look at that. Some of that hats I am seeing-the puff part is as hard as a rock and certainly higher than 4mm so I will still wonder what that 'hardness' is on those. Thanks for your info - the actifeed setting was a huge help!

[Juli in Kona]

I have seen these really high and really firm 3D hat designs. If I see another one here at home, I am going to buy it and take it apart. I agree that it is not the foam we use. The sides are too squared off - our foam gets rounded. So, I think that the foam they use is much firmer and much thicker (maybe 2 layers) than our regular puff foam.

Juli in Kona