FAQs - Hats

       Placement Embroidery file size Embroidery type
           Front            4″ × 1.75″          Flat & 3D
   Side & back logo              2″ × 1″

         Flat & 3D

 Low Profile Dad Hat Embroidery Area

Embroidery types

Flat embroidery

Custom Embroidered Hat with Flat Embroidery

  • Flat embroidery is a technique where stitches are embroidered flat on the shirt
  • Minimum thickness for shapes: 0.05″ (1.3 mm)
  • We use satin stitch for shapes between 0.05″ (1.3 mm) and 0.5″ (12.5 mm)
  • We use tatami stitch for shapes thicker than 0.5″ (12.5 mm)
  • Minimum height for lowercase letters: 0.25″ (6.4 mm)
  • Minimum height for uppercase letters: 0.3 (7.6 mm)
  • Any text smaller than 0.25″ (6.4 mm) in height will be a run stitch

3D puff embroidery

Custom Embroidered Hat with 3D puff Embroidery

  • 3D puff is a technique where embroidery is raised with a foam insert under the stitching. It's used mostly for big shapes
  • Minimum thickness for shapes: 0.2″ (5.1 mm)
  • Maximum thickness for shapes: 0.5″ (12.7 mm)
  • Minimum height for letters: 0.75″ (19.1 mm)
  • Minimum space between the elements is 0,07″ (1,8 mm)
  • 3D puff isn't available for side and back logos

Partial 3D puff embroidery

Custom Embroidered Hat with partial 3D puff Embroidery

  • Partial 3D puff is a technique where both flat embroidery and 3D puff are used in the same graphic. See above for more details on each
  • Minimum of 0.05 (1.3 mm) spacing between 3D puff objects

Must-follow guidelines

  1. Design true-to-size graphics
    The graphics you upload must be true to their size on the end product.
  2. Use solid shapes and colors only
    Don't include photographic images, gradients, fade or blend effects. Elements like these cannot be embroidered.
  3. Use transparent backgrounds
    Graphics should include transparent backgrounds. Elements outside the main design will be picked up and result in unwanted embroidery stitches on the end product.
  4. Outline your fonts
    All fonts should be converted to outlines unless your graphic is in PNG format. That way you don't have to send us the font files.
  5. Submit vector files in EPS or PDF format
    We highly recommend submitting your embroidery graphics as vector files (EPS or PDF). Raster graphics (PNG) can be used as well if the resolution of the graphic is at least 300 DPI.
  6. Stay within the maximum stitch count
    If your graphic covers a very large part of the embroidery area, it may exceed the maximum limit of 15,000 stitches. In such case, your order will be put on hold.
  7. Remove embroidery file template guidelines
    If you use our downloadable templates, delete the guide layers before saving your files. If you don't delete them, they'll be embroidered.


Digitization is a process that converts your design file to a format that supports embroidery.

  • Text-only designs cost only $3.95  to digitize.
  • For other designs digitization costs $6.50 per file. Each embroidery type (flat/3D/partial) requires a separate digitized file. You can re-use your digitized files for future orders of the same embroidery type. 
  • Digitization for designs placed on the back or sides of the hats costs $2.95.
  • Stitch density and direction differ in hat and apparel embroidery. If you want to use hat files for shirt embroidery and vice versa, the files need to be adjusted for $2.95 per file. 3D or Partial 3D puff files can't be adjusted, so they have to be digitized from scratch for $6.50.
  • We only digitize files when they're part of an order.
  • Our digitization process is designed to match our machine capabilities, so we don't accept files that have been digitized elsewhere.

Tips for best results

  • Remember the side and back design option
    You can embroider a small design (e.g. your logo) on the back or either side of the hat. The design will be embroidered in flat embroidery.
  • Follow our embroidery guidelines

  • Create embroidery-unique designs
    Embroidery is not printing, so most graphics that work on other products won't be suitable for embroidery. 
  • Keep it simple
    Clean designs with bold lines and text work best for embroidery. If your design is too complex (e.g. contains gradients or intricate details), your order will be put on hold.

Common Issues

  • Text too small, lines too thin

    Avoid using very small letters because the embroidered text might not be legible. Keep the text at least 0.25'' in height and at least 0.05'' thick.

    The minimum recommended line thickness for the regular satin stitch is 0.05''. For thinner lines we’ll use run stitch (a single line of stitches).

    You can measure the text in Illustrator either by using the measuring tool, or by converting the font point size to inches.

  • Distressed or textured graphics

    With distressed or textured graphics many details might be lost during embroidery depending on the texture size. For these files, we’ll only be able to use flat embroidery, and extremely thin parts are likely to be run stitched.
  • Solid backgrounds

    Graphics that cover a large part of the embroidery area will likely exceed the maximum stitch count of 15,000. Remove all backgrounds from your files to make sure they don't exceed this count.

    If you’d like to keep the background, we’ll have to reduce the size of the graphic by up to 50%.