Process for making three-dimensional foam-laid nonwovens

A method for making a high topography nonwoven substrate, the method comprising:

• generating a foam including water, a foaming agent, and a plurality of fibers, the plurality of fibers comprising synthetic binder fibers;
• providing a template form;
• templating the foam to create a foam/form assembly;
• heating the foam to dry the foam and bind the synthetic binder fibers;
• and
• removing the template form after heating to provide the substrate, wherein the substrate includes a base layer having an X-Y surface and a backside surface opposite the X-Y surface, the base layer having a density;
• and
• a plurality of projection elements integral with and protruding in a Z-direction from the X-Y surface, wherein each projection element has a height, a diameter or width, a cross-section, a sidewall, a density, a proximal end where the projection element meets the base layer, and a distal end opposite the proximal end, and wherein the density of a projection element is the same as the density of the base layer.