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Custom Embroidery

We offer on demand embroidery (thread art) on various hats and beanies with no minimum order. Take your brand to the next level with branded hats.

This method of embellishment is different than our other production methods. Not all images work great for embroidery and you must take the time to consider what makes good artwork for embroidery, as it isn't the same as DTG printing, by reviewing our Artwork Requirements tab below. 

  • No minimums

  • High quality embroidery

  • We ship worldwide

  • Printed/shipped under YOUR BRAND

  • The following hats and beanies are currently available for embroidery on demand:

    Flexfit Washed Cotton Dad Hat (Yupoong 6997)

    • $18.00
    • Contents: 98% Cotton / 2% Spandex
    • Sizes: S/M (6 3/4” – 7 1/4”) | L/XL (7 1/8” – 7 5/8”)
    • Adjustable: No
    • Additional Features: Lightly structured. Garment washed cotton for vintage appeal. Classic low-profile cap. Matching under-visor. The quintessential dad hat.
    • Visor: Curved
    • Panels: 6
    • Colors: White, Black, Khaki, Navy

    Adult 5-Panel Classic Trucker Cap (Yupoong 6006)

    • $16.00
    • Contents: 47% Cotton / 25% Polyester / 28% Nylon
    • Sizes: One Size Fits All
    • Adjustable: Yes, Plastic Snap
    • Additional Features: Ideal for embroidery. Contrast trucker mesh. Matching plastic snap. Hard buckram. Matching under-visor.
    • Visor: Flat
    • Panels: 5
    • Colors: Black, Black/White, Brown/White, Charcoal, Charcoal/White, Navy, Navy/White, Pink, Red, Red/Black, Royal/White, Silver/Black, White

    Classic Trucker Hat (Yupoong 6006W)

    • $16.00
    • Contents: 47%cotton/25% polyester/28% nylon
    • Sizes: OS
    • Adjustable: Yes
    • Additional Features: 4" crown structured with buckram backing, white front solid panel, four mesh panels, eight rows of stitching on a flat visor with matching under-visor and plastic adjustable closure.
    • Visor: Flat
    • Panels: 4
    • Colors: White/Royal Blue, White/Black, White/Brown, White/Carolina-Blue, White/Red, White/Pink, White/Navy, White/Kelly

    Classic Snapback Hat (Yupoong 6089)

    • $16.00
    • Contents: 80% Acrylic / 20% Wool
    • Sizes: One size fits all
    • Adjustable: Yes - Plastic snap
    • Additional Features: Classic shape. Premium wool blend. Matching plastic snap. Hard buckram. Classic green under-visor.
    • Visor: Flat
    • Panels: 6
    • Colors:Spruce, Heather Grey, Royal Blue, Red, Purple, Silver/Black, Purple/Black, Teal/Black, Black/Natural, Navy Blue, Dark Grey, Black, Camo

    Flexfit Wooly 6-Panel Cap (Yupong 6277)

    • $18.00
    • Contents: 63% Polyester / 34% Cotton / 3% Spandex
    • Sizes: S/M (6 3/4" – 7 1/4") | L/XL (7 1/8" – 7 5/8")
    • Adjustable: No
    • Additional Features: Athletic Shape. Hard buckram. Silver under-visor. Look and feel of wool. 8 rows of stitching on visor.
    • Visor: Curved
    • Panels: 6
    • Profile: Mid
    • Colors: Dark grey, silver, royal blue, red, purple, navy blue

    Distressed Trucker Hat (Adams OL102)

    • $16.00
    • Contents: 100% cotton front panel and visor, 100% nylon mesh back panel
    • Sizes: S/M (6 3/4" – 7 1/4") | L/XL (7 1/8" – 7 5/8")
    • Adjustable: Yes - Plastic snap
    • Additional Features: Distressed torn visor, cotton twill sweatband; four rows of stitching on bill, pigment-dyed front panels, plastic tab back closure; Cool-Crown™ mesh lining
    • Visor: structured
    • Panels: 6
    • Profile: Mid
    • Colors: Forest/Tan, Khaki/Tan, Miss Mud/Tan, Nautical Red/Tan, Navy/Tan, Royal/Tan

    Peached Cotton Twill Dad Cap (6245PT)

    • $15.50
    • Contents: 100% Cotton
    • Sizes: One Size Fits all
    • Additional Features: Antique Buckle Closer, 6-Panel Unstructured Low-Profile
    • Colors: Black, Diamond Blue, Light Grey, Maroon, White


    Knit Beanie w/cuff (Yupoong 1501)

    • $14.00
    • Contents: 100% Hypoallergenic Acrylic
    • Sizes: One Size Fits All
    • Additional Features:  Super dense knit. Hand washable.
    • Length: Approximately: 12"
    • Colors: Spruce, Heather Grey, Royal Blue, Red, Navy Blue, Black
    Beanie w/Cuff

    Knit Beanie (Yupoong 1500)

    • $14.00
    • Contents: 100% Hypoallergenic Acrylic
    • Sizes: One Size Fits All
    • Additional Features:  Super dense knit. Hand washable.
    • Length: Approximately: 8.5"
    • Colors: Navy Blue, Red, Royal Blue, Black, White
    Embroidered Beanie

  • Artwork File Requirements

    Download our Embroidery Templates

    Guide to setup artwork for embroidery digitizing

    Embroidery Styles

    Embroidery can be done in two different visual styles. These two types can be used for the same design but must be specified when your artwork is digitized.

    • Flat Embroidery. Basic embroidery with that is flat except the thickness of the thread.
    • 3D Puff Embroidery. This is a technique of adding an embroidery foam into your design which makes your design stand up or "puff". Designs that use puff needs a certain width to look good. The preferred width for puff is between 1/4" and 1/2". When having your artwork digitizing it is important to tell the digitizer which areas will be 3D and which will be flat as it is set in the file. 3D Puff will use about 2X the amount of stitches as flat embroidery.

    Line/3D Puff/Outline Requirements

    • Minimum letter height: 1/4" (about 20-22 point font)
    • Minimum thickness of 3D puff: 1/4"
    • Maximum thickness of 3D puff: 1/2"
    • Minimum text height with outline: 1/2"
    • Minimum color outline: 1.5MM/4pt


    When doing embroidery please make sure your art is limited to the following colors:

    Embroidery Color Options

    Allowed File Types

    • DST

    Embroidery Size

    • We are unable to resize the artwork in DST files and so you must provide the files at the exact size it should be embroidered.


    All files for embroidery need to be digitized. This is the process of converting the artwork into commands that can be read by an embroidery machine.  You can get your own files digitized or submit a request for us to do it for $10. We require a DST file type for all embroidery and as mentioned above we have a 10K stitch limit on all hats. Vector art is recommended but if you just have raster it will work if it is high enough resolution (i.e. 300DPI). When supplying the art make sure that all fonts are converted to shapes/outlined/rasterized so we don't need the font when we open the file.

    Do I need to re-digitize if I want to change colors? No, just supply a clear mockup file and we can change the thread colors without needing to re-digitize a file.

    Do I need a separate file digitized for the brimmed hat vs beanie? You do if you want them at different sizes.

    Stitch Limitations

    The max amount of stitches  for embroidery on hats is currently 10,000 stitches. Stitch count is the number of stitches it will take to replicate your artwork. Text on a hat at 5"x2" is plenty enough stitches but doing a full color 5"x2" filled in completely would be way too many stitches for our service.

    How to estimate embroidery stitch counts

    Download the grid below and place your image on top of the file. Count the number of boxes your design fills and find the number in the chart. This is just an estimate to help you make sure your art is less than 10,000 stitches which is our maximum stitch out at this time.

    Embroidery Stitch Count Chart

    Download the grid in PDF

    • 1 solid square inch of embroidery = 2000 stitches
    • 1 solid square of 1/4 inch of embroidery = 125 stitches
    • Colors and artwork details will impact the number of stitches above.
    • Straight lines under logos take around 200 extra stitches per inch.
    • Outlines will add 3X the amount of stitches.
    • 3D Puff will add 2X the amount of stitches

    Examples of stitch counts






    Artwork No-Nos

    • Shadows, color gradients or sharing increases the complexity and not recommended through our service.
    • Letters that are too small or certain fonts such as those in serifs (small points or thin lines at the ends of the letters i.e. Times Roman) do not embroider well as the lines are too small.
    • Letters with excessive outlines or on letters that are less than 1/2" high.
    • Fonts below 20PT lose the unique features.
  • How to order

    Our embroidery service is on-demand and requires no minimum order but does require a few more steps to get setup because it requires specially digitized files for embroidery.

    Step 1: Setup your art file. See Artwork Requirements tab.

    Step 2: Email support your art in the template.

    Step 4: If your artwork works for embroidery Printaura will request $10 per file to prepare your artwork for embroidery.

    Step 5: After payment Printaura will digitize your files and activate hats in your account.


  • Samples of embroidered hats

    distressed trucker embroidery hat example

    embroidery example

    flatbrim embroidery hat example

    embroidery example

    flexfit embroidery hat example

    embroidery example

    flexfit embroidery hat example

    embroidery example


    Uses 3D Puff for all letters

    Embroidery Sample


    3D Puff Vs No Puff

    3D Puff

    3D puff example

    No Puff

    no puff example