How to Create 3D Hat Embroidery - E15 Lesson 12

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How to Create 3D Hat Embroidery - E15 Lesson 12

Written by Tia Isom

Published on September 21, 2026

Modified on September 21, 2026

Reading time for 4 min

Today, we’ll show you how to create 3D hat embroidery on the E15 Embroidery Machine. If you’re new to standard cap embroidery, we recommend starting with our foundational tutorial: How to Embroider a Hat - E15 Embroidery Machine Lesson 3. This guide focuses specifically on 3D hat embroidery, where EVA foam is used to create a raised, dimensional effect.

Table of Contents

Introduction
Materials You’ll Need
Part 1: Hooping the Cap
Part 2: Setting Up the Design
Part 3: Adding EVA and Embroidering
Finishing Your 3D Hat Embroidery
Tutorial Video
Conclusion
FAQ

Key Takeaways

Use a 3D-ready embroidery design, cap stabilizer, and EVA foam for raised hat embroidery.
Hoop the cap with the stabilizer, fold the sweatband outward, and align the metal retaining strip along the brim seam.
Select Cap Hoop, attach the cap to the Cap Driver, and listen for a click on both sides.
Set the speed to 500 SPM for 3D hat embroidery. The E15 supports up to 800 SPM for cap embroidery, but 500 SPM is recommended until you’re comfortable.
For complex designs, complete the first embroidery pass before adding EVA for the second pass.
After embroidery, press both side locks, rotate the brim parallel to the X-axis, and remove the cap.

Introduction

3D hat embroidery adds height and dimension to cap designs, making logos and lettering stand out with a clean, professional finish. The process is similar to standard cap embroidery, but the key difference is the use of EVA foam and a design digitized for 3D effects.

In this tutorial, we’ll walk through hooping the cap, preparing the design, adding EVA, and embroidering on our multi-needle embroidery machine.

Materials You’ll Need

Before you begin, gather the following items:

Blank cap
Cap embroidery stabilizer
EVA foam
3D embroidery design

Materials for 3D hat embroidery on an HTVRONT embroidery machine, including a blank cap, cap stabilizer, and EVA foam

Most importantly, you’ll need a 3D embroidery design. These designs are digitized with the proper underlay and coverage to work with foam.

Note: Hat embroidery files and apparel embroidery files are not always interchangeable. We recommend choosing an embroidery file designed specifically for hats.

3D embroidery designs displayed on an E15 embroidery machine touchscreen for hat embroidery

Part 1: Hooping the Cap

Insert the stabilizer into the hoop slot.
Fold the sweatband outward.
Center the cap on the hoop.
Position the metal retaining strip of the cap frame along the seam between the cap brim and the front panel.
Lock the clips to secure the cap in place.
Press both side locks down and remove the cap hoop.
Then, go to Frame Select and select Cap Hoop.
Next, install the hooped cap onto the machine.
Keep the brim horizontal and attach the cap to the Cap Driver.
Rotate the cap to align the positioning grooves.
You will hear a click from both sides when the cap is locked in place.

Part 2: Setting Up the Design

1. Select a Design

Select a design file made for 3D hat embroidery.

2. Confirm the Hoop Type

Make sure the hoop type is set to Cap Frame.

3. Set Thread Colors

Next, tap Color Setup. Adjust the design colors based on your preference.

Tapping Color Setup on the E15 embroidery machine touchscreen

Adjusting design colors on the E15 embroidery machine touchscreen

4. Use Pattern Trace

Next, use Pattern Trace to check the embroidery area.

Using Pattern Trace to check the embroidery area on the E15 embroidery machine

Part 3: Adding EVA and Embroidering

Next, place the EVA on the cap surface and secure both ends with tape.

Note: For complex 3D hat designs, complete the first embroidery pass before adding EVA for the second pass.

Next, set the speed to 500 SPM. The E15 embroidery machine supports cap embroidery speeds up to 800 SPM, but we recommend 500 SPM for 3D hat embroidery. Once you’re more comfortable with the process, you can gradually increase the speed.
Then switch the machine to embroidery mode and press the Start button to start embroidering.
After embroidery is complete, press both side locks and remove the cap hoop.
Rotate the brim until it is parallel with the X-axis, then remove the cap hoop and cap completely.
Finally, release the locks on the Cap Hoop and remove the cap.

Finishing Your 3D Hat Embroidery

Your 3D hat embroidery is complete!

Completed 3D hat embroidery on a cap, showing the raised dimensional design

Tutorial Video

If you prefer to follow along visually, the video below walks through the same process from hooping the cap to removing the finished cap. You can watch it before you start or use it alongside the steps above.

Conclusion

You’ve now learned how to create 3D hat embroidery on the E15 Embroidery Machine. By combining the right stabilizer, a 3D-ready design, and EVA foam, you can produce raised embroidery with a clean, professional finish. Be sure to test different EVA thicknesses and designs to see what works best for your project.

Next tutorial: Large Flat Frame Embroidery. In the next lesson, we’ll show you how to set up and embroider large flat frame projects on the E15. Stay tuned!

FAQ

What is EVA foam used for in 3D hat embroidery?

EVA foam is placed under the embroidery to create height, giving the design a raised, puffy 3D effect.

Can I use any embroidery design for 3D hat embroidery?

It’s best to use a design specifically made for 3D hat embroidery. These designs are digitized with the proper underlay and coverage for foam.

What speed should I use for 3D hat embroidery?

For 3D hat embroidery, we recommend 500 SPM. The E15 embroidery machine supports cap embroidery speeds up to 800 SPM, but 500 SPM gives you better control. Once you’re comfortable, you can gradually increase the speed.

Why do I need to complete the first pass before adding EVA for complex designs?

For complex 3D designs, completing the first embroidery pass helps secure the design and improves the final result before adding EVA for the second pass.

How do I know the cap is locked in place?

You will hear a click from both sides when the cap is properly locked.

Ready to create raised, dimensional designs on caps?

Explore the E15 Embroidery Machine

Keep Learning

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