Too narrow and the foam never rises. Too wide and the column chews a trench. We size puff satins to the foam thickness you name in the brief, then leave inner counters open.
Puff is a different file
3D puff digitizing is not a setting on a flat cap file. Foam needs wide columns, a cut-away path, and simple shapes. Thin script should stay flat or move off the cap. If the same mark also sews on a polo, order a separate left-chest punch.
What to write on the quote
Finished letter height, foam thickness if you already buy a brand, and whether the run is structured or unstructured. Attach artwork on the quote form. Streetwear examples sit in the embroidery digitizing portfolio.