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Domestic Decoration Techniques

Flat Embroidery with #40 Poly Thread
Flat Embroidery with #40 Poly Thread
Flat Embroidery with #40 Poly Thread

Flat Embroidery is one of the most popular and used decoration technique for OTTO caps. It fits any budget and can really compliment a variety of cap styles.

File Type Accepts *.EPS, *.AI, *.PDF, *.TIFF, *.JPG formats. Raster Files at 300 DPI. If you already have a digitized artwork file, please submit it in DST or EMB file format.
Maximum Colors 8 colors. Regular / Multi Color / Neon / Metallic thread available. See OTTO Thread Chart for reference.
Maximum Size Cap Front: 4.5” W x 2.25” H, Cap Back: 3.5” W x 1.25” H, Side: 2.5” W x 1.5” H (Approximate)  For more sizing information and options, please check the size chart below.  
Special Instruction Avoid gradient, shading, transparency, distressed and other similar elements in the artwork. Recommended for best results text letter size must be at least .25′′ high or a font size of at least 24 at the final embroidered size. Anything below 1mm size is subject to error (gaps between artwork may close and artwork may become distorted.

* Works great on 6 panel & 5 panel caps.

Flat Embroidery - Metallic Thread
Flat Embroidery with Metallic Thread

Metallic Flat Embroidery can add vibrant shine to any logo. If you are looking for something eye catching, this is the way to go.

File Type Accepts *.EPS, *.AI, *.PDF, *.TIFF, *.JPG formats. Raster Files at 300 DPI. If you already have a digitized artwork file, please submit it in DST or EMB file format.
Maximum Colors 1 color. See OTTO Thread Chart for reference.
Maximum Size Cap Front: 4.5” W x 2.25” H, Cap Back: 3.5” W x 1.25” H, Side: 2.5” W x 1.5” H (Approximate)  For more sizing information and options, please check the size chart below.  
Special Instruction Avoid gradient, shading, transparency, distressed and other similar elements in the artwork. Recommended for best results text letter size must be at least .25′′ high or a font size of at least 24 at the final embroidered size. Anything below 1mm size is subject to error (gaps between artwork may close and artwork may become distorted.

* Works great on 6 panel & 5 panel caps.

3D Embroidery with #40 Poly Thread
3D Embroidery with #40 Poly Thread
3D Embroidery with #40 Poly Thread

Looking for depth and dimension for your logo? 3D embroidery can provide that using a variety of color options. This decoration type transforms your cap completely by adding a raised surface to your design.

File Type Accepts *.EPS, *.AI, *.PDF, *.TIFF, *.JPG formats. Raster Files at 300 DPI. If you already have a digitized artwork file, please submit it in DST or EMB file format.
Maximum Colors 8 colors. Regular / Multi Color / Neon / Metallic thread available. See OTTO Thread Chart for reference.
Maximum Size Cap Front: 4.5” W x 2.25” H, Cap Back: 3.5” W x 1.25” H, Side: 2.5” W x 1.5” H (Approximate)  For more sizing information and options, please check the size chart below.  
Special Instruction

Avoid gradient, shading, transparency, distressed and other similar elements in the artwork. Recommended for best results text letter size must be at least .25′′ high or a font size of at least 24 at the final embroidered size. Anything below 1mm size is subject to error (gaps between artwork may close and artwork may become distorted.

3D embroidery requires the artwork to consist of large, solid areas of color. All elements in the design should be at least .25” in width. Thin lines and small details can not be embroidered using this method.

* Works great on 6 panel & 5 panel caps.

3D Embroidery - Metallic
3D Embroidery with #40 Poly Thread

3D embroidery using metallic thread not only provides dimension to any design, but also luminous shine.

File Type Accepts *.EPS, *.AI, *.PDF, *.TIFF, *.JPG formats. Raster Files at 300 DPI. If you already have a digitized artwork file, please submit it in DST or EMB file format.
Maximum Colors 1 color. See OTTO Thread Chart for reference.
Maximum Size Cap Front: 4.5” W x 2.25” H, Cap Back: 3.5” W x 1.25” H, Side: 2.5” W x 1.5” H (Approximate)  For more sizing information and options, please check the size chart below.  
Special Instruction

Avoid gradient, shading, transparency, distressed and other similar elements in the artwork. Recommended for best results text letter size must be at least .25′′ high or a font size of at least 24 at the final embroidered size. Anything below 1mm size is subject to error (gaps between artwork may close and artwork may become distorted.

3D embroidery requires the artwork to consist of large, solid areas of color. All elements in the design should be at least .25” in width. Thin lines and small details can not be embroidered using this method.

* Works great on 6 panel & 5 panel caps.

Plastisol Heat Transfer for Custom Hats
Plastisol Heat Transfer
Plastisol Heat Transfer
Plastisol Heat Transfer
Plastisol Heat Transfer

Plastisol heat transfer is a printing technique that combines the use of plastisol ink and special release paper. Popular on 5 panel caps with colorful designs.

File Type Accepts *.EPS, *.AI, *.PDF, *.TIFF, *.JPG formats. Raster Files at 300 DPI.
Maximum Colors 8 colors
Maximum Size Cap Front: 4.5” W x 2.25” H, Cap Back: 3.5” W x 1.25” H, Side: 2.5” W x 1.5” H (Approximate)  For more sizing information and options, please check the size chart below.  
Special Instruction Avoid gradients, small text sizes, thin lines and fine details to achieve the best printed results. At least 1pt line thickness is required in design artwork and negative space. While creating your graphics stick to using areas of solid color and a specific color palette. Remember that the more colors used in a design, the higher the cost will be to print it.

* Works great on 5 panel caps.

Digital Print Heat Transfer - Glossy Finish
Digital Print Heat Transfer - Glossy Finish
Digital Print Heat Transfer - Matte Finish
Digital Print Heat Transfer - Matte Finish
Digital Heat Transfer

Digital print heat transfer can be applied with a gloss finish for high luster or a matte finish for fine detailed images. Perfect for various styles of designs. Recommended on 5 panel caps.

File Type Accepts *.EPS, *.AI, *.PDF, *.TIFF, *.JPG formats. Raster Files at 300 DPI.
Maximum Colors No color limit. Choice of Glossy or Matte finish.
Maximum Size Cap Front: 4.5” W x 2.25” H, Cap Back: 3.5” W x 1.25” H, Side: 2.5” W x 1.5” H (Approximate)  For more sizing information and options, please check the size chart below.

* Works great on 5 panel caps.

Full Color Print Vinyl Heat Transfer on Seam Panel
Full Color Print Vinyl Heat Transfer on Seam Panel
Full Color Print Vinyl Heat Transfer on Seam Panel
Full Color Print Vinyl Heat Transfer on Seam Panel
Full Color Print Vinyl Heat Transfer on Seam Panel
Full Color Print Vinyl Heat Transfer on Seam Panel / Flat Panel

Full color print vinyl heat transfer can be applied effortlessly over the seam to 6 panel & 5 panel caps. A great way to display your detailed designs.

File Type Accepts *.EPS, *.AI, *.PDF, *.TIFF, *.JPG formats. Raster Files at 300 DPI.
Maximum Colors No color limit.
Maximum Size Cap Front: 4.5” W x 2.25” H, Cap Back: 3.5” W x 1.25” H, Side: 2.5” W x 1.5” H (Approximate)  For more sizing information and options, please check the size chart below.

* Works great on 6 panel & 5 panel caps.

Vinyl Applique Glitter & Glitter Flake Heat Transfer on Custom Hats
Vinyl Applique Glitter & Glitter Flake Heat Transfer
Vinyl Applique Glitter & Glitter Flake Heat Transfer
Vinyl Applique Heat Transfer

Flat Embroidery is one of the most popular and used decoration technique for OTTO caps. It fits any budget and can really compliment a variety of cap styles.

File Type Accepts *.EPS, *.AI, *.PDF, *.TIFF, *.JPG formats. Raster Files at 300 DPI.
Maximum Colors 1 color. Fashion-FILM® / Glitter / Glitter Flake™ available.
Maximum Size Cap Front: 4.5” W x 2.25” H, Cap Back: 3.5” W x 1.25” H, Side: 2.5” W x 1.5” H (Approximate)  For more sizing information and options, please check the size chart below.
Special Instruction Avoid gradients, small text sizes, thin lines and fine details to achieve the best printed results. At least 1pt line thickness is required in design artwork and negative space.

* Works great on 6 panel caps.

Foil Material Transfer - Gold
Foil Material Transfer - Silver
Foil Material Transfer - Rose Gold
Foil Transfer Print

Foil Material Transfer is perfect for adding a metallic finish to your design. Simply select a color from one of our options and make your design stand out and shine.

File Type Accepts *.EPS, *.AI, *.PDF formats.
Maximum Colors 1 color. Choice of Gold / Silver / Rose Gold.
Maximum Size Cap Front: 4.5” W x 2.25” H (Approximate)  Recommend on 5 Panel caps only. For more sizing information and options, please check the size chart below.
Special Instruction Avoid gradients, small text sizes, thin lines and fine details to achieve the best printed results. At least 1pt line thickness is required in design artwork and negative space.

* Works great on 5 panel caps.

TPU Thermaprint
TPU Thermaprint -  Metallic Finish
TPU Thermaprint -  Matte Finish
TPU Thermaprint -  Mirror Finish
TPU ThermaPrint (3 inch max.)

A TPU patch transfer is the perfect three dimensional decoration applied to your cap. This modern technique allows you to showcase your design by using "liquid metal" technique or a matte look if you prefer. Your text is clear and very sharp with this decoration technique.

File Type Accepts *.EPS, *.AI, *.PDF, *.TIFF, *.JPG formats. Raster Files at 300 DPI.
Maximum Colors 6 colors. Choice of Metallic / Matte / Chrome finish.
Maximum Size (Width + Height) ÷ 2 < 3 inch. For more sizing information and options, please check the size chart below.

* Works great on 6 panel & 5 panel caps.

Patch - Embroidered
Embroidered Patch (3 inch max.)
File Type Accepts *.EPS, *.AI, *.PDF, *.TIFF, *.JPG formats. Raster Files at 300 DPI. If you already have a digitized artwork file, please submit it in DST or EMB file format
Maximum Colors 8 colors
Maximum Size (Width + Height) ÷ 2 < 3 inch. For more sizing information and options, please check the size chart below.

* Works great on 6 panel & 5 panel caps.

Patch - Woven
Woven Patch (3 inch max.)
File Type Accepts *.EPS, *.AI, *.PDF, *.TIFF, *.JPG formats. Raster Files at 300 DPI.
Maximum Colors 8 colors
Maximum Size (Width + Height) ÷ 2 < 3 inch. For more sizing information and options, please check the size chart below.

* Works great on 6 panel & 5 panel caps.

Patch on Custom Hats
Patch - Sublimated
Sublimated Patch (3 inch max.)
File Type Accepts *.EPS, *.AI, *.PDF, *.TIFF, *.JPG formats. Raster Files at 300 DPI.
Maximum Colors No color limit.
Maximum Size (Width + Height) ÷ 2 < 3 inch. For more sizing information and options, please check the size chart below.

* Works great on 6 panel & 5 panel caps.

Patch on Custom Hats
Screen Printed Patch (3 inch max.)
File Type Accepts *.EPS, *.AI, *.PDF, *.TIFF, *.JPG formats. Raster Files at 300 DPI.
Maximum Colors 6 colors
Maximum Size (Width + Height) ÷ 2 < 3 inch. For more sizing information and options, please check the size chart below.

* Works great on 6 panel & 5 panel caps.

Patch on Custom Hats
Faux Leather Deboss Patch (3 inch max.)
File Type Accepts *.EPS, *.AI, *.PDF, *.TIFF, *.JPG formats. Raster Files at 300 DPI.
Leather Color Choice of Light Brown / Dark Brown / Black
Maximum Size (Width + Height) ÷ 2 < 3 inch. For more sizing information and options, please check the size chart below.

* Works great on 6 panel & 5 panel caps.

Patch - PVC
PVC Patch (3 inch max.)
File Type Accepts *.EPS, *.AI, *.PDF, *.TIFF, *.JPG formats. Raster Files at 300 DPI.
Maximum Colors 4 colors
Maximum Size (Width + Height) ÷ 2 < 3 inch. For more sizing information and options, please check the size chart below.

* Works great on 6 panel & 5 panel caps.


 

Headwear & Accessory Styles
Style Approximate Embroidery & Heat Transfer Area
5 Panel Foam Front High Crown Styles Embroidery Not Recommended 4.5” W x 2.5” H
5 Panel Low Profile Styles 5” W x 2.25” H
5 Panel Mid Profile Styles 5” W x 2.5” H
6 Panel Low Profile Styles 5” W x 2.25” H
6 Panel Mid Profile Styles 5” W x 2.5” H
Beanie (Reversible) Style No. 91-1234 Embroidery Not Recommended 4.5” W x 2.5” H
Beanie Styles 4.5” W x 2.5” H
Biker Style Head Wrap Please Consult with Custom Order Department

Bucket Hat (Washed Pigment Dyed)

Style No. 16-200

4.5” W x 2” H/span>
Camper Cap Styles 4” W x 1.5” H
Hat Band 4.5” W x 1” H
Military Styles 4.5” W x 1.25” H
Painter Cap 4.75” W x 2.25” H

Running Cap Style

No. 133-1047

Heat transfer not recommended 3.5” W x 2” H

Running Cap

Style No. 133-1252 / 133-1244

4” W x 1.5” H
Sun Visor Styles 4.5” W x 1.25” H
Youth Headwear Styles
Style Approximate Embroidery & Heat Transfer Area
Youth 5 Panel Foam Front High Crown Styles Embroidery Not Recommended 4” W x 2.25” H
Youth 6 Panel Low Profile Styles 4.5” W x 2.125” H
Youth 6 Panel Mid Profile Styles 4.5” W x 2.25” H
Youth Bucket Hat (Washed Pigment Dyed) Style No. 63-217 3.75” W x 1.25” H
Youth Sun Visor Styles 4.25” W x 1.125” H
Embroidered, Printed, Designed Headwear Styles
Style Approximate Embroidery & Heat Transfer Area
Style No. 114-815 (Reflective Piping Design) Top 3" W x Bottom 4" W x 2.25" H
Style No. 19-701 (Piping Design)  Top 3" W x Bottom 4" W x 2.25" H
Style No. 57-174 (U.S. Flag Pattern) 2.75” W x 2.25” H
Style No. 58-755 (U.S. Flag Flame Pattern)  Top 4” W x Bottom 3” W x 2.25” H
Style No. 80-585 (U.S. Flag Design) Top 4” W x Bottom 4.5” W x 2.25” H
Style No. 87-478 (Flame Pattern)  3” W x 2.25” H
Standard Patch Sizes
Shape Approximate Patch Size 
Square Size A 2” W x 2” H
Square Size B 2.25” W x 2.25” H
Square Size C 2.5” W x 2.5” H
Rectangle Size A 3” W x 2” H
Rectangle Size B 4” W x 2” H
Circle Size A 2” W x 2” H
Circle Size B 2.25” W x 2.25” H
Circle Size C 2.5” W x 2.5” H
Oval Size A 3” W x 2” H
Oval Size B 3.5” W x 1.5” H

Patch sizes are calculated by adding the width (W) and the height (H), then divided by two. Example: 4” W + 2” H = 6” ÷ 2 = 3”

Standard Profiles
Shape Description
Low Profile

Low Profile

A fitted cap style with a shallow crown.

Mid Profile

Mid Profile

A crown height between the low profile and high crown.

High Crown

High Crown

A deep profile with single front panel.