Puffy Foam is used in embroidery to pad stitching to give a three dimensional look. Sulky produce packs of this foam in 2mm and 3mm thicknesses. You need to use foam that tears easily. Not all foam sheets will work. Possible uses for this technique are lettering on hats, decorative projects and artworks including wall hangings.
Recently I shared a link on the Machine Embroidery and Digitizing Facebook Page to an article published by Wilcom on digitizing for Puffy Foam. I remembered doing a Puffy Foam design some time ago and thought I would share my experience and provide some additional tips.
I chose A chinese symbol, because traditionally they are created using a paintbrush, and therefore the individual parts don’t have blunt ends. Normal lettering has blunt ends, and as explained in the Wilcom article these are areas where the foam might poke out unless you digitize some covering stitches.
For those of you who are using the Bernina software, I set the Satin Stitch Spacing (density) to 0.23 (the default is 4). This is nearly twice as dense as normal. I made sure Satin Stitch was selected (not Satin Special) so that there were no needle penetrations in the middle of the design, and I deselected the underlay.
I was not in Artistic Mode and I had view Needle Points selected. As you can see some of the areas of the design were too wide for normal satin and the software has replaced the stitches with jump stitches and needle points. I decided to use the reshape tool to change the angle of the stitching to fix this problem. I also kept an eye out to avoid any long stitches forming along the outline of the object.