Puffy Foam

[Juli in Kona]

I am trying to stitch out 3 letters that I bought from EmbLibrary specifically for Puffy Foam, 1" high. I have the presser foot all the way up, and the the Actifeed at 9. I am using a contrasting color of foam so I can see what is going on and there are plenty of gaps. Thought it would do better than that. Any suggestions on settings?

Juli in Kona

[Body Cover]

Well first off, Auto Actifeed at 9 sounds really low. We sew normal hats at 9 to 11 on regular settings (no Auto Actifeed) when using the standard and puffy foam, were usually more like 20 to 25 and the density should be very low around a 2, I know that you bought the letters for foam, so they should be close, I've heard of people running the job twice with mixed results.
it will work if nothing moved, if you don't understand when the job finishes, instead of taking off the hoop just hit start again.
Just a little FYI though, even the big companies have show through, I went on a tour at Richardson Cap and was surprised to see a large group of people poking foam in with what looked like a glorified flattened pointy chopstick but the end was the size of a toothpick, it would be easy to use a toothpick but also easy to break them, then an industrial heat gun is used but can be very touchy and ruin hats, but you heat the lettering and the foam actually shrinks slightly, and pulls the pokies in so that most of them don't show. Also you can see why you try to match the foam color to the thread color your using. This is a process to say the least and the results are way cool,
but it is definitley a trial and error thing, (in my opinion) we also ran the machine slower like 750 SPM, and used a new sharp needle to help cut through the foam easier.
Good Luck, hope some of this helps

Ron

[Juli in Kona]

I bumped the Actifeed up to 23, kept the presser foot all the way up and matched the foam to the thread color. Actually, it looks good. So, I am going to go ahead and run the hats. Thanks Ron.

Juli in Kona