Learn About Embroidery

The PErfect HAt Starts With Perfect Thread

Cotton Blends

Cotton is the most common custom hat fabric we embroider on. Cotton can be blended with other fabrics to produce new fabrics (like canvas or denim) with different performance characteristics.

Wicking Hats

Popular fabrics often used in custom baseball and golf hats –  wicking cotton fabrics were designed to evaporate moisture quickly so you (and your custom embroidered hat) keep cool and dry. 

Mesh Hats

Mesh is a typically made from a  polyester and is woven with large holes to provide maximum hat and head ventilation. Our custom trucker hats are a prime example of a mesh hat we can customize

Wool Hats


A wool baseball cap is always great to have. Wool is a soft and durable fabric that’s great for heat insulation. The crown is made of 6 panels of wool blend fiber with 6 ventilation sewn eyelets in each panel. 

Embroidery Basics

Embroidery is a fashion decoration technique, which uses a needle and thread to create words and or images on products. It’s not unique to hats, though it is the most common method for decorating hats. Embroidery can be done by hand or with a machine. Our state-of-the-art facility uses 9 Barudan embroidery machines. Most embroidered hats are created using machines with multiple needles; each needle having it’s own thread color. An embroidery hoop is a tool that holds the hat and fabric in place while the hat is being embroidered. Hoops come in a variety of sizes but not all machines accommodate all hoop sizes for hat backs, fronts and sides.  Ours do.

Domestic embroidery can accommodate two stitching techniques: flat stitch and 3D. As mentioned earlier, there are also more stringent requirements on decoration size and location. Here is a list of stitching options typical – and possible for – embroidered hats.

Flat Embroidery

The most popular and cost efficient way to brand a cap is through Flat embroidery. Flat embroidery can accommodate for more complex lettering, offering more variations of spacing and sizes than 3D embroidery. You can still feel the thread, but because it takes up less space it is easier to accommodate longer words or phrases. We embroider caps using this method via a computer-controlled sewing machine that accurately reproduces your logo or graphic on a cap.

3 Dimensional Embroidery

Three dimensional embroidery or (3D embroidery) emerges from the surface of the cap and has the most dramatic texture. Your text or logo is not only highly visible but can be felt in contrast to the panels where it is stitched. Decorating a cap using this effect can literally enable your logo to pop up from the surface of a cap by up to 5 millimeters. 3D embroidery is thicker and takes up more space on the cap and is best used for small amounts of lettering making a bold impact. This type of decoration is the more expensive (and time consuming) method when embroidering caps. 

An extensive list of available stitch styles:

  • Applique Embroidery
  • Asynchronous Stitch
  • Bamboo Pattern
  • Broken Stitch
  • Chain Stitch
  • Chenille Embroidery
  • Circle Stitch
  • Cloudy Stitch
  • Cross Pattern
  • Dot Stitch
  • Edging Embroidery
  • Flannel Embroidery
  • Foam Stitch
  • Gradient Embroidery
  • Grain Stitch
  • Hairy Embroidery
  • Herringbone Pattern
  • Intertexture
  • Irregular Stitch
  • Mesh Stitch
  • Net Pattern
  • Pattern Fill Stitch
  • Plaid Stitch
  • Rhinestone Embroidery
  • Saw Tooth Stitch
  • Sequins Embroidery
  • Shaved Flat Stitch
  • Snow Stitch
  • Stone Stitch
  • Threadless Stitch
  • Weaving Pattern
  • Wheat Stitch
  • Yarn Embroidery
  • Zig Zag Stitch
  • Specialty Shapes

Custom Hats | Custom Teams | Custom Looks