Custom embroidered caps and hats
A cap is the most constrained garment we decorate. The usable area on the front panel is about four and a half inches across and a little over two inches tall, there is a seam down the middle of it, and behind that panel sits a layer of buckram that decides how crisply a needle can work. Almost every disappointing cap order comes from artwork drawn without knowing those three facts.
The usable areas
| Position | Maximum | Notes |
|---|---|---|
| Front panel | 4.5 in wide × 2.25 in tall | Sits about 0.5 in above the brim seam; the centre seam splits it |
| Side panel | 2.5 in wide | Left or right; often a secondary mark or a year |
| Back panel | 2 in wide | Above the closure. Small marks only |
| Brim | 2 in wide | Front edge or underside; needs a flat brim to sit properly |
| Bucket hat brim | 3 in wide | More room than a cap, and no crown seam |
Cap styles, and what each one takes
| Style | Crown | Decoration it suits |
|---|---|---|
| Structured snapback | Stiffened with buckram, high crown | Direct embroidery and 3D puff — the sharpest results |
| Trucker | Foam front, mesh back | Direct embroidery and applied patches; mesh takes nothing |
| Dad cap | Unstructured, soft, low profile | Direct embroidery at modest size; detail softens |
| Fitted | Structured, closed back | Direct embroidery; no back-panel closure to work around |
| Bucket hat | No crown panels | Brim and side embroidery, or an applied patch |
Four ways to decorate a cap
| Method | What it is | Best for |
|---|---|---|
| Direct embroidery | Stitched into the panel | Bold logos and lettering above about 5 mm |
| Applied patch | An embroidered, leather or PVC patch sewn or heat-sealed on | Detail the crown cannot hold; also the cheapest route to a premium look |
| Flat print | Printed onto the panel | Photographic artwork or a long colour list |
| 3D puff | Foam under the stitch, so lettering stands proud | Bold block letters and simple shapes only |
Specification
| Item | Standard |
|---|---|
| Styles | Snapback, trucker, dad, fitted, bucket, beanie |
| Decoration | Direct embroidery, applied patch, flat print, 3D puff |
| Colours | Nine standard thread colours; Pantone on request |
| Sampling | Sample approved before every bulk run |
| Pricing | Quoted on the blank, the quantity and the decoration |
| Lead time | 10–12 business days standard, 5–7 rush |
How ordering works
- Send artwork. Any format — a logo file, a photo of an old patch, or a sketch on paper.
- Approve the proof. You get a digital proof with the size, colours and border marked. Nothing runs until you sign it off.
- Production. 10–12 business days as standard, 5–7 on a rush, at no extra charge.
- Tracked delivery. Shipped worldwide, to you or straight to your printer.
Common questions
My logo is wider than the front panel. What now?
Three options, in order of how well they usually work: redraw it stacked rather than wide; run it across the front and the two side panels as a set; or put it on a patch and let the patch overhang the seam. The proof will show you which one your artwork survives.
Can you embroider a mesh trucker back?
No. Mesh has no substrate to hold a stitch. A patch can be applied to the foam front, and the back stays plain.
What is 3D puff, and when should I avoid it?
Foam is laid under the stitching so lettering rises off the cap. It looks excellent on thick block letters and terrible on anything thin or detailed — the foam shows through and the edges go ragged.
Ready to quote your caps?
Tell us the cap style, the quantity and where the logo goes, and we will show you what fits inside the panel before anything is stitched.
Related reading
- Patch placement guides — measured positions, including cap front and side
- Custom embroidered patches — for detail the crown cannot hold
- Leather patches — the classic cap-back patch