Flat Embroidery with #40 Poly Thread

Flat Embroidery is one of the most popular and used decoration technique for OTTO CAP^®s. 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

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.

Maximum Size

8 colors. Regular / Multi Color / Neon / Metallic thread available. See OTTO Thread Chart for reference.

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 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

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 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 Chartfor 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.

DTF

DTF delivers crisp, high-detail images, making it ideal for a wide variety of design styles. Recommended for both 5-panel & 6-panel caps.

File Type

Accepts *.EPS, *.AI, *.PDF, *.TIFF, *.JPG formats. Raster Files at 300 DPI.

Maximum Colors

No color limit. 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.

Screen Print

Screen print is one of our most popular decorating techniques. It adds to any design! Add it directly to the cap or an applique, either way, you have endless color combinations and looks with screen printing.

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 6 panel & 5 panel caps.

Metallic Screen Print

Metallic screen printing is perfect for adding some "POP" to your design. It is less than boring and showcases your design with a little shine.

File Type

Accepts *.EPS, *.AI, *.PDF, *.TIFF, *.JPG formats. Raster Files at 300 DPI.

Maximum Colors

1 color.

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 & 5 panel caps.

Heat Transfer Printing

Using CMYK color mode, Heat transfer printing uses heat to apply your design the panels of your cap. You are not limited to a specific amount of colors, this makes this the perfect decoration technique for designs with an assortment of color.

File Type

Accepts *.EPS, *.AI, *.PDF, *.TIFF, *.JPG formats. Raster Files at 300 DPI.

Maximum Colors

No color limit. 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.

Sublimation Transfer

Looking for a vibrant printing technique for your design? Sublimation allows you to showcase your detailed designs. This is achieved by printing the vibrant full color design to white polyester fabric.

File Type

Accepts *.EPS, *.AI, *.PDF, *.TIFF, *.JPG formats. Raster Files at 300 DPI. CMYK color mode.

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 5 panel caps.

Foil Material Transfer

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.

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.

Woven Patch with Merrowed Edge

If you are looking for a patch decoration, a woven patch emblem with merrowed edge is a good choice. Your design is woven and then is finished with a merrowed edge which prevents fraying of your design. You have the option of creating a matching color theme or if preferred, you can use a contrasting color merrowed edge to make it "POP" more.

File Type

Accepts *.EPS, *.AI, *.PDF formats. Raster Files at 300 DPI.

Maximum Colors

8 colors

Maximum Size

Regular size: Width x Height < 9 sq. inch. Oversize (extra charge): Width x Height = 9 to 12 sq. inch. For more sizing information and options, please check the size chart below.

* Works great on 6 panel & 5 panel caps.

Woven Patch with Embroidery Edge

This option allows you to achieve a clean patch look. Your design is a woven, and then finished with an embroidery edge to prevent it from fraying. The embroidered edge allows for a smoother look.

File Type

Accepts *.EPS, *.AI, *.PDF formats.

Maximum Colors

8 colors.

Maximum Size

Regular size: Width x Height < 9 sq. inch. Oversize (extra charge): Width x Height = 9 to 12 sq. inch. For more sizing information and options, please check the size chart below.

* Works great on 6 panel & 5 panel caps.

Embroidered Patch with Merrowed Edge

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

Regular size: Width x Height < 9 sq. inch. Oversize (extra charge): Width x Height = 9 to 12 sq. inch. For more sizing information and options, please check the size chart below.

* Works great on 6 panel & 5 panel caps.

Faux Leather with Deboss Patch

File Type

Accepts *.EPS, *.AI, *.PDF, *.TIFF, *.JPG formats. Raster Files at 300 DPI.

Maximum Colors

Not applicable. Deboss nature color.

Maximum Size

Regular size: Width x Height < 9 sq. inch. Oversize extra charge): Width x Height = 9 to 12 sq. inch. For more sizing information and options, please check the size chart below.

* Works great on 6 panel & 5 panel caps.

Silicone Rubber Patch

A silicone rubber patch is a modern embelishment that adds style and texture to your design. This technique allows us to create a fully customizable look. Text is crisp and clear.

File Type

Accepts *.EPS, *.AI, *.PDF formats.

Maximum Colors

4 colors.

Maximum Size

Regular size: Width x Height < 6 sq. inch. Oversize (extra charge): Width x Height = 6 to 9 sq. inch. For more sizing information and options, please check the size chart below.

* Works great on 6 panel & 5 panel caps.

Woven Fold Label on Top Center of Back Arch

Make your logo seen from every angle of the cap by adding this decoration. A woven fold label of your design can be applied to the top center of the back arch for added detail to your cap.

File Type

Accepts *.EPS, *.AI, *.PDF formats.

Maximum Colors

3 colors.

Maximum Size

Standard size.

* Works great on 6 panel & 5 panel caps.

Woven Fold Label on Left of Back Closure

A woven fold label is a great way to showcase your logo on your cap. We can apply it to the left back closure for added brand detail to your cap.

File Type

Accepts *.EPS, *.AI, *.PDF formats.

Maximum Colors

3 colors.

Maximum Size

Standard size.

* Works great on 6 panel & 5 panel caps.