The hoop and the area
The cap hoop holds the cap on a cylinder; the embroidery area is about 60 mm tall by 100 to 140 mm wide depending on the machine, on a curved surface. The design must fit within 55 mm in height to avoid the sweatband seam and the crown, and stay 10 mm from the peak. The studio's placement guide offers "cap, front" with these dimensions and carries them over to the run sheet.
The stitching order
On a curved, stretched surface, the fabric moves during embroidery. To keep the elements aligned, you sew from the centre outwards (the central part is fixed first, then the fabric is pushed outwards, not inwards) and from bottom to top (from the peak towards the crown, in the direction where the fabric is best held). Text is therefore sewn letter by letter from the middle to the left, then from the middle to the right, not from left to right. The studio applies this order with "Optimise order" when the cap placement is chosen; check it in the simulation.
Density, underlay, stitches
- Structured cap (heavy cotton with buckram): density 0.38 mm, contour + tatami underlay, compensation 0.25 mm. The fabric is stable.
- Unstructured cap (dad hat, soft cotton): density 0.40 mm, cross tatami underlay, compensation 0.35 mm, cap tear-away stabilizer.
- Satins: no wider than 7 mm; beyond that, split or fill.
- Centre-run underlay under text satins so that they do not sink into the thick fabric.
- Running stitches: triple stitch to be visible on the textured fabric.
On the machine
Speed 600 rpm (500 on wide satins), 80/12 ballpoint needle on thick caps, tension slightly increased, full bobbin (a bobbin stop on a cap is a pain). On a multi-head, check that every cap is stretched the same way: a loose cap gives a design that is offset from one head to the next.
The file
A cap logo is 5 to 7 cm wide and 3,000 to 6,000 stitches. Text 15 mm tall in satin, 2,000 to 3,000 stitches. The file is the same as for a flat garment, with the cap order and the cap densities; the studio's "Cap" reference fabric sets everything at once. Format according to the machine: DST for industrial machines, PES for Brother PR, JEF for Janome MB.
Frequently asked questions
What is the maximum size on a cap?
55 to 60 mm tall, 100 to 140 mm wide depending on the hoop. The machine manual gives the exact area.
Why is my text offset?
Left-to-right stitching order on a curved surface. Redo it from the centre outwards.
Can I embroider on the peak or the side?
The side yes, with a cap hoop and a design under 40 mm; the peak no, except on special machines.
Go further
The studio is free to draw, open and check designs. Your first machine file takes five minutes.
Updated 2026-09-24.