The first thing to remember is there are many different varieties of caps and subtle changes that sometimes need to be made when doing embroidery on them. We will examine several of the more popular types you will run across. Note: The height limitation may vary a little from one style to another for all types of caps.

Low profile constructed caps: First constructed hats have what is called buckram behind the front panels. It usually, but not always, looks and feels like a harder plastic. This type cap is usually easier to embroider on because the buckram will help limit the amount of shifting that will occur. The design height for this type of cap is 2.5 inches high and 14 inches wide. The standard cap hoop can be used here.

High profile constructed caps: This type of hat usually has a foam back instead of buckram. Stitches tend to sink into them. They look like 1970's baseball hats. Really High. Sometimes the buckram for this style of cap is not firmly attached and you can move it. The design height for this type of cap is 3.0 inches high and 14 inches wide. The 270 cap hoop can be used here.

Low profile unconstructed: These caps do not have buckram behind the front panels, it is only material. These caps are popular, but are difficult to embroider on since they tend to shift more during the embroidery process. The design height for this type of cap is 2.2 inches high and 14 inches wide. While a 270 cap hoop can be used, it is recommended to use a Standard cap hoop for this type of cap.

6 panel caps: Have a seam that runs down the center of the front of the cap. You have a slightly higher chance of thread breaks when you embroider over these seams because the thread can rub against them. There is also a greater chance that the design and/or lettering will be distorted if/when the stitches cross over the seams.

4 panel caps: Do not have a seam running down the front center of the cap.

Lettering on Caps

If you are doing lettering on any of these caps you may want to adjust how it sews out. On flat goods lettering usually sews from left to right. For caps it is important to break the lettering up so that when it sews it will go ½ the way from left to right and the other ½ from right to left. This will decrease the amount of push/pull you will encounter with these types of caps.

Example: Take the name Joshua. We want the first three letters to sew from left to right and the last three to sew from right to left. Type in the name in a Helvetica Medium font, once it is on the main work area click on your object selector:

Next click on the letter J. A screen will pop up that looks like this:

Click on Yes and you should see a box appear around the letter J. Now click on one of the 14 other colors you have to choose from on the needle bar. Repeat this for each character in the word. Once you are done it should look like this:

Next click on the Color Sequence icon:

When it pops up it should look something like this:

Next use the up/down arrows on the lower left side of that screen to change the sewing sequence of the word. Click on #6 and using the up arrow move it to the #4 position. Next move what is now the # 6 spot to the # 5 position. The sequence should now look something like this:

Now click OK. Next click on your object selector and left click and drag a box around the word. Then, click on a color to make the lettering a single needle change again. When this is completed your word will now sew in the following sequence: J,O,S, from left to right, then A,U,H from right to left. For those with level 2 and higher software you can verify the stitching sequence by clicking on the Display drop down menu, click on Slow Draw and hit F5. This should show you exactly how this will sew out.

Adjusting the sewing sequence of the lettering is something you will want to do especially if you are adding lettering to a design that will either be positioned above/below a design on a cap in any line type. Remember as well if you are digitizing a design specifically for a cap you will want it to sew from the center out when possible.