3D Embroidered Hats: Raise Your Design to the Next Level

Let's be real, we all either have (or know someone who has) wayyy to many hats falling of the hooks in the closet. Sure, there are plenty of different hat styles out there, but if you really want to create a hat that everyone will pick from the hooks time and time again it's time to focus on leveling up the design and take it 3D.

There are a couple of 3D options to really make your design pop: puff embroidery and 3D embroidered patches. Both create stunning results, so let's dive into each so you can discover which option hits the mark for your next custom hat order. 

Puff Embroidery

Puff embroidery is created by placing foam down on your selected hat (or garment,) sewing over the top with the thread color of your choice and then removing the excess foam and thread. For the best result, you'll want to stick with designs that have bold elements and thick lines (5mm minimum.)

And if you want to create a little extra interest, you can have a portion of your design embroidered with the standard method and select an element or two to pop out with puff.

3D Embroidered Patches

For an extra unique, high-quality look, 3D embroidered patches can take your design to the next level. These stellar patches use high-quality embroidery and custom-cut foam to create a 3D look that is sure to stun your crew. No need for sticking to standard ovals, circles, or squares. These patches can be totally customized to any shape you like. So go wild with that tiger mascot -- we've got the stitching skills to really make it roar.

And just like with puff embroidery, you can select certain details of your design to stay flat with the embroidery and let the bold elements really pop out with the 3D effect.

Choosing Your Method

In all honesty, when you're picking between puff embroidery and a 3D patch, you really can't go wrong—both are going to create a completely unique effect. However, if your design is going on a lighter, unstructured hat, we'd recommend going with puff embroidery to keep things a little lighter. And if there are super fine details that you'd like to capture in your design, go with the patch and keep those flat while letting the bold elements pop out.

Selecting Your Hat

If you're interested in turning heads with your design, then selecting the right hat is crucial. We have plenty of different styles of hats to choose from -- bucket hats, dad caps and everything in between. Here are a few helpful things to consider when selecting your hats:

Who's going to be wearing the hats?

If it's a big group of men and women, go with something unstructured and adjustable to fit a wider range of head sizes.

How large is your custom design?

If you have a large design for the front panel of the hat, make sure you're selecting a hat with a taller crown and plenty of room to work with.

Are you looking for a standout color?

If you need something outside of the standard blues, blacks and khakis, check out hats that have a large range of color options available.

Are these hats for an event outdoors?

Pick a lightweight hat that's ready to help beat the heat.

Ready to stand out and bring your custom hat order to life?

We're here to help. Our team of apparel experts can help you choose between puff embroidery and 3D patches—and find the perfect that your crew will want to wear over and over. Contact us now or start browsing our selection of hats to get your order rolling.