Cheryl, The post Herb gave about the capped ends is great. It is right on about the underlays as well. A Double ZigZag at about a 12 to 14 density with an edgewalk to help cut the edges is the recipe. Density is set higher than normal. The Lettering you are doing is going to need some editing to widen the letters and cap the ends, but it probably can be set up for Puffy Foam. I wonder about the .5 inch, that is pretty small? There is a lady on this list by the name of Janel Harris who may be able to help you. She is a digitizer and is much more familiar with the details than I am. I heard from her yesterday and she is on a road trip right now so I am not sure if she is doing email or not? Janel's Email address is janel@xxxxxxxxxxxxxxx Perhaps she can give some suggestions as well. The trick to getting rid of the little stick out pieces is to use a Heat Gun. They can be purchased at a Hobby Store. The "heat gun" gets hotter than a normal hair dryer. When you heat it (after tearing off the excess), the little goobers or pieces sticking out shrink into the stitches of the thread. Do not over heat, you can scorch the thread or the fabric. Also, try to get Foam that is as close to the color of the thread you are using as possible. Using a black foam with black thread does not show as bad as black foam with white thread. In any case, it can be a challenge. Jeff Banks Melco Embroidery Systems ----- Original Message ----- From: "Cheryl Rotter" <tsiemb@xxxxxxxxxxxxx> To: <amayausers@xxxxxxxxxxxxx> Sent: Tuesday, February 08, 2005 12:09 PM Subject: [amayausers] 3D Foam Question I need some help with 3D Foam application on Visors. Visor is 2 inches tall and has a Brody Script one line design measuring ½ inch tall. I have been playing with density and fabric thickness but I still see little tiny raggedy pieces of foam showing on the outside of the column stitches. I am using underlay; edge walk and a center walk to tack down the foam. What density do you suggest for both the column and the underlay? Any other suggestions??? I am a brand new embroiderer (since November) any help is greatly appreciated. Cheryl Rotter Team Sports Ink 5111 Grumann Dr. Ste #1B Carson City, NV 89706 775-884-3550