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Embroidered With Personality: Common Embroidery Methods for Baseball Caps

Published On: February 6, 2026    By: kailyn

Embroidered Custom Hats

Introduction

Embroidery and prints are frequently seen on clothing and hats. For the clothing and accessories industry, these are essential design elements. Therefore, from a consumer’s perspective, understanding some basic embroidery knowledge is very helpful when choosing clothes or hats.

Baseball cap, embroider your own style! Let the show begin!

There are three common embroidery methods for baseball caps: Flat Embroidery, 3D Puff Embroidery, and Appliqué Embroidery.

Flat embroidery

Embroidery is done flat on the surface of the fabric, and it feels slightly flat and stiff to the touch.

Knowledge Sharing: On lower-end baseball caps, you often see the connecting lines between patterns or letters in the flat embroidery not being cut. This is because the embroidery machine is running at high speed and embroidering the entire pattern in one go; the machine cannot stop to cut the threads. This step can only be done by a worker after the embroidery is finished. Some low-quality baseball caps are also very cheap, so this thread-trimming step is omitted to save costs. Keep this in mind when buying hats.

Raised embroidery

This type of embroidery incorporates filler, creating a three-dimensional effect. It’s also called 3D embroidery. You can feel the raised texture to the touch. When purchasing raised embroidery, pay attention to whether the embroidery thread has loose threads; check this carefully.

Applique embroidery

A piece of fabric or leather (called an applique) is placed on the hat, and embroidery is done on the applique. Some appliques have frayed edges, which is a design style. Some appliques have cleaner edges (as shown in the picture below).

Patch Embroidery

First, make an embroidered patch, then attach the patch to the hat.

Embroidery is frequently used in clothing, but the embroidered area is generally small. Large embroidered areas can make clothing uncomfortable to wear. (There’s a type of densely embroidered jersey that effectively solves the problem of large-area embroidery and comfort, which I’ll discuss later!) Hats are even more suitable for embroidery than clothing.

Embroidery enhances the overall texture of a hat. Hat designs also include large embroidered areas and full-coverage embroidery, making the hat look like a work of art. Of course, the more embroidery and the larger the area, the higher the cost and the more expensive the hat will be.

Large-area embroidery

The whole embroidered

Warning: This content may trigger trypophobia! 🙂

The entire embroidered headdress (back)

Expert View from Aung Crown

When choosing a hat to match your outfit, make sure the baseball cap is of good quality and coordinates harmoniously with your clothes, shoes, and handbag. Wearing a cheap, low-quality hat from a street vendor is a major turn-off! Learn a little about embroidery, and wearing a good quality baseball cap will definitely enhance your style!

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