A method of manufacturing an article (10; 10A; 10B; 110; 110A; 310; 410), the method comprising: disposing one or more spacer layers (28; 28A, 28B) at a bobbin side of a base sheet so that an inner side of the one or more spacer layers (28; 28A, 28B) is at the bobbin side of the base sheet; driving a needle thread through both the base sheet and the one or more spacer layers (28; 28A, 28B) with a needle of an embroidery machine according to a programmed first pattern that provides a series of loops (18; 18J) of the needle thread that extend outward from the bobbin side of the base sheet through the one or more spacer layers (28; 28A, 28B) and engage with a bobbin thread disposed at an outer side of the one or more spacer layers (28; 28A, 28B); bonding the needle thread to a needle side of the base sheet opposite from the bobbin side of the base sheet; removing the bobbin thread; and moving the one or more spacer layers (28; 28A, 28B) away from the base sheet to slide the one or more spacer layers (28; 28A, 28B) off of the series of loops (18; 18J), wherein the needle thread is a fusible thread, and wherein bonding the needle thread to the needle side of the base sheet includes applying heat to the needle thread at the needle side of the base sheet, or wherein the method of manufacturing further comprises applying adhesive to the needle side of the base sheet for bonding the needle thread to the needle side of the base sheet; or prior to driving the needle thread through the base sheet, disposing a meltable bonding layer against the needle side of the base sheet, wherein driving the needle thread through the base sheet further comprises driving the needle thread through the meltable bonding layer, and wherein bonding the needle thread to the needle side of the base sheet includes applying heat to the meltable bonding layer. disposing one or more spacer layers (28; 28A, 28B) at a bobbin side of a base sheet so that an inner side of the one or more spacer layers (28; 28A, 28B) is at the bobbin side of the base sheet; driving a needle thread through both the base sheet and the one or more spacer layers (28; 28A, 28B) with a needle of an embroidery machine according to a programmed first pattern that provides a series of loops (18; 18J) of the needle thread that extend outward from the bobbin side of the base sheet through the one or more spacer layers (28; 28A, 28B) and engage with a bobbin thread disposed at an outer side of the one or more spacer layers (28; 28A, 28B); bonding the needle thread to a needle side of the base sheet opposite from the bobbin side of the base sheet; removing the bobbin thread; and moving the one or more spacer layers (28; 28A, 28B) away from the base sheet to slide the one or more spacer layers (28; 28A, 28B) off of the series of loops (18; 18J), wherein the needle thread is a fusible thread, and wherein bonding the needle thread to the needle side of the base sheet includes applying heat to the needle thread at the needle side of the base sheet, or wherein the method of manufacturing further comprises applying adhesive to the needle side of the base sheet for bonding the needle thread to the needle side of the base sheet; or prior to driving the needle thread through the base sheet, disposing a meltable bonding layer against the needle side of the base sheet, wherein driving the needle thread through the base sheet further comprises driving the needle thread through the meltable bonding layer, and wherein bonding the needle thread to the needle side of the base sheet includes applying heat to the meltable bonding layer.