Hat Embroidery Size Guide: Front, Side, Back and Visor

The right size makes a cap look professional. Too big and the design wraps around the crown and distorts. Too small and it looks lost. These are the ranges we work to for most caps on commercial cap frames.

Front panel

Cap style	Max width	Max height
Structured six-panel	4.5 in	2.25 in
Unstructured	4.25 in	1.75 in
Low profile	4.0 in	1.75 in
Trucker	4.5 in	2.5 in

The front has a center seam on most six-panel caps. Stitches over the seam sink slightly, so we avoid putting small text or fine lines right on it.

Side panels

Left and right sides fit about 2 to 2.5 inches wide and up to 1.75 inches tall. Initials, flags, numbers and small icons work well. Long text does not.

Back arch

The back sits above the strap opening. A common size is 2.5 inches wide by 1 inch tall. Arched text that follows the opening looks natural.

Visor

The bill is stiff and curved, so designs stay small and simple, usually under 3 inches wide and 0.75 inches tall.

From the production floor: when a customer asks for "as big as possible" on the front, we usually suggest 0.25 inches less than the maximum. The design looks better centered and the edges stay clear of the crown seams.

Check your design with the hat placement size guide, then send it for a quote.