question about puffy.

I tried to do a hat with the logo, which is all lettering, with puffy material underneath to make it really stand out. The design stitched beautifully without it. When I put the puffy material on, it came out with the stitches all separated. I tried it on a different type of hat, and it stitched beautifully with and without the puffy. The customers hat has a center seam while the test hat has no seam. Do I need to re-digitize the logo for puffy material? It was originally done for the hat with the center seam without using puffy.