Printing & Embroidery

How to Embroider on Caps

Whether you want to make a hat for yourself or give a gift to a loved one, there are several ways to make a custom cap. The most popular area for embroidery is on the front, but there are other popular areas for embroidery, too. You can use flat stitches to write a slogan or a design. You can also engrave on both sides, though the space is limited. For more information about how to embroider on caps, read this article!

Flat embroidery

When choosing a custom embroidery design for a cap, flat embroidery is best. This method uses a flat surface to stitch the embroidery, whereas 3D Puff uses a foam insert underneath the design to create a 3D effect. This method is best suited for simple designs, such as logos or symbols. There are some disadvantages to flat embroidery, however. We will cover these below. Also, you should choose a cap design that is easy to change.

3D puff

If you’re in the business of embroidering custom hats, you may have heard of the 3D puff embroidery technique. This technique is a popular way to add depth to any cap design, and it’s especially appealing when done with a cap made of a unique fabric. However, it has its disadvantages. A poorly-done 3D puff will lead to downtime, and the resulting cap will likely end up in the trash. Then, you’ll have to spend more time on post-production cleaning, which can increase your costs.

Underlay stitches

The five basic types of Underlay Stitches used in cap embroidery are Zig-Zag, Edge Walk, Corner, and Overlay. You can apply Underlay Stitches manually, or use software that will do this for you. Underlay stitches help to strengthen the edge and provide lift to the cap’s design. These stitches are often used on embroidered baseball caps. Listed below are examples of some of the stitches commonly used for underlay stitches.

Merrowed edge

The merrowed edge is the edge stitching on fabric patches that prevents fraying and is commonly known as a scout patch. This type of stitching is especially useful for embroidered patches because it can accommodate designs that are either simple or have a moderate amount of detail. This type of stitching is also commonly used for uniforms, such as high school letterman jackets and police badges.

Post-Patch iron-on seal

A Post-Patch iron-on seal is an excellent way to create a professional looking patch. It is easily applied to a cap embroidery project using a hot iron. To iron a patch, you simply sandwich it between two pieces of teflon and apply heat for about 15 seconds. Be sure to leave a small slit in the backing of the patch so that it will be easier to remove. The Post-Patch iron-on seal works great for this purpose, and it is a relatively inexpensive way to give your cap embroidery a professional finish.

Structured vs unstructured caps

Both structured and unstructured baseball caps have different advantages. Structured baseball caps tend to be more formal and suited for uniforms, while unstructured baseball caps are more casual and comfortable. Unstructured baseball caps, also known as Fiddler or Mariner’s caps, are much lighter and have less structure to them. A structured baseball cap will always have buckram inside, whereas an unstructured one will not. To learn more about cap embroidery visit