Challenges, Problem, and Solutions for Custom Hat Embroidery

Headwear is one of the hardest digitizing products. Digitize in a limited space with pellicle fabric types and create kinky designs is not very simple. Some embroiders does not count headwear or hats in their digitizing products.

 These products need extra concentration for the perfect design. Commonly, these products are not so easy to make, so here we are providing you some materials and techniques. Some challenges and their solutions for headwear are listed below.

1. Bucket Hats

Challenges:

Bucket hats have less space that makes it more complicated for embroiders. Bucket hats usually got air holes and snaps, which makes the space much lesser for the designs. Furthermore, these have some fabric on the bottom of the crown that is typically unfavorable for the digitizing machines.

Solution:

Unfortunately, there is no way to get rid of these ‘not so solve’ problems. Find a way to deal with them and create designs on the front and backside of a hat in the coolest possible way. It needs experience and techniques for digitizing a design or print in a small place.

2. Visors

Challenges:

Visors have quite small space than the bucket hats. You can only digitize a design on the front side because there is no space on the backside. They are convoluted too, as in comparison with bucket hats.

Solutions:

There is less space on the front side of the visor. These visors will let you digitize a high design of 1.25 inches with a width of 4-5 inches. If there is a demand for designing on the corners, then make it from 1.25 inches to 1 inch. Moreover, educate your customer with the space problem and let them understand the space issues. But if they are stick with their idea, then try things out to make it.

3. Snapbacks

Challenges:

Distortion and bending in snapback occurs during the production process. Furthermore, a limited space is present at the center front.

Solution:

The only solution to this problem is the trimmers that straighten the bills during the process.

4. Toques

Challenges:

Toques or beanies created by a fleece or knitted fabric that disappears the design in a fabric. Their problems occurred due to the respective material. All sides are available for design. Occasional stripes are the only obstacle in it.

Solution:

Especially for logos, use selective stitches like solid fill stitch to make a design prominent. Otherwise, the pattern will disappear into the fabric. For instance, find a perfect place on the toques through which design will look astonishing and definable.

5. Caps (five and six panels)

Challenges:

These caps are free from space issues, but the main problem is that a design is fading in the fabric. Front foam panel embroidery creates issues.

Solution:

Thin fonts can resolve the above issues and avoid fine designs. In five-panel caps, there is not centered seam for design, but it is present in six-panel caps. Also, they are visible and easy to read.