Guide to Mastering Embroidered Hats

Imagine this, you woke up late and one thing leads to another. Then you stop and think to yourself, “It’s a hat day!” I can assure you that you are not the only person that was met with this scenario. Sometimes life just slaps you across the face and at that moment there is nothing better than a good old fashion hat. A hat can legitimately save someone’s day. Be a hat hero! Get started today. 

We have plenty of hats to choose from. Let’s dive on in and look at some of the most sold hats and some of the reasons why you might want to add a particular hat to your online catalog.

Twill Cap

Twill cap can sometimes be considered baseball caps because of the stiffer, supportive fabric that holds its shape making it clear how it should be worn.


In this case, our snapbacks are six panel wide hats, with a flat brim and adjustable back. This type of hat is popular among individuals who express interest in music festivals, raves, and concerts. It pulls the whole outfit together and protects the individual from the beating sun. Snapbacks are rave classics.

Trucker Hat

Call it a trucker hat, mesh or netback cap it’s still considered a type of baseball cap. These hats are used as a promotional material. In the early 2000s this type of hat was typically associated with hip-hop, pop-punk and skater culture. Celebrities have been endorsing the hot trend from the early 2000s. Trucker hat is a great piece of gear for trail and urban runners. They give protection against the sun while the design makes them an excellent and lightweight alternative to most hats.

Baseball Cap

If you think baseball caps are just for your favorite baseball players, I hate to break it to you – they make a popular fashionable piece. It might be a 39-year-old invention but this simple hat continues to break through all kinds of fashion trends. The baseball cap is a must-have accessory piece to accompany the so-called athleisure trend.

Dad Cap

Dad caps aren’t just for dads anymore. They provide a comfortable everyday fit. Dad caps hug heads of all shape and sizes making it easy to order these as gifts.

Slouchy Beanie

Winter isn’t just about staying warm, beanies can compliment an outfit in a way no other hat can. Beanies are a popular fashion accessory to those who live in colder climates and are looking to add a little creativity into their day-to-day wardrobe. Beanies are a staple of a winter wardrobe. Some people have a shoe weakness others have a profound beanie-mania. It’s only a matter of time and resources to find your beanie-obsessed audience.

Fleece Hat

Every person in a cold-weather climate needs one of these fleece headpieces. Fleece hats are must-have accessories for any adventurous soul. Fleece accessories are designed to keep your customers warm wherever they go. These performance-like accessories are great for any outdoor activity – running, cross-country, skiing, ice skating, snowshoeing, ice fishing and more.

Many store owners make the same mistakes, over and over again. Don’t be one of them. Embroidery and direct-to-garment printing are completely different processes, so taking a shirt design and using it as hat design won’t do your design any justice.

Embroidery designs require a minimalist approach. Complicated designs are too difficult to embroider – our machines only have a certain capacity to embroider designs. In case of embroidery, less is technically more. Use bold designs with thick lines to achieve the best look.

PRO TIP: In the embroidery world, less is more.

Additionally, embroidery has limited color options. Shading is not recommended. If you are planning to use multiple colors, please make sure to have large enough details for our machines to properly embroider your designs.

We offer 16 different colors. We suggest using no more than a 2 color gradient. Don’t let the word gradient fool you, the artwork will still look like it’s embroidered of solid colors. 

For our visual observers, we have this little neat table below.  

Best Practices

  • Stick to fonts that are larger than .18″ in height
  • Solid font if smaller than 1”
  • No drop shadow or outlines around the text if it is smaller than .5″ in height
  • Fill all objects containing negative space under .2”W x .2”H (transparencies) with a solid color
  • NOTE: Distressed fonts may be simplified without notice to the seller or customer


  • 4″ x 2.4″ Max 

Do's & Dont's

Avoid Small Details

Embroidery comes with detail  limitations. Your designs should not include thin lines or intricate details. 

Avoid Small Text

To ensure that your design has legible text, artwork must be a certain dimentions – 4″ x 2.4″ Max. 

Avoid Gradients

Use color-blocking technique to achieve a gradient effect.

Avoid Using Negative Space

Designs with negative space can result in scrunched fabric. We recommend that you fill negative spaces with a solid color to avoid design problem. 

See an example of how to fix gradient and negative space below. 

  • No Gradients Allowed
  • Small Negative Spaces Allowed 
  • Negative spaces were color-matched to our thread colors 
  • Color was added to fix small negative spaces 
Original Design
Modified Design

Additionally, we do NOT recommend using photos on embroidery garments. Photos are significantly modified into simple shapes and WILL NOT look anything like your original image. 

File Formats

  • High resolution .png (with transparent background)
  • .jpg files (minimum 1200x1200px at 300 dpi)
  • Photos taken from a cell phone at 72dpi
  • Vector formats .ai, .svg, and .eps 

Design Inspiration


Every once in while everyone gets down. We can all use something to look up to, a short quote or a word that speaks to the soul. An inspirational message can be just about anything. Inspiration comes and goes, you never know when your design reaches the right soul at the right time to change someone’s world.


Food is one of those things that people love to talk about. Generally, you can find common interest once you start talking about food you love. People will fall head over heels for hats that portray little icons of food just to show the world what they are about.


OK, OK! Pets are men’s/women’s best friend. Your customers will welcome the idea of having their favorite animal with them at all times. Additionally,  you can appeal to outdoor enthusiasts who enjoy wild-game hunting.

Now that you know everything there is to know about embroidery, go on give it a shot! We suggest ordering a few samples before you start selling to get a better idea of how our embroidery machines work. Plus samples can be used for brand ambassador marketing – I call this a win-win situation.  

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