When I did embroidery I only used Cobra Cap. But I also picked 4 different styles of the 6 panel caps to offer the customers. If you throw down a cap catalog for the customers they will pick caps that are not made for embroidery. It will also cause you to order caps that will only be used for that particular customer leaving you with a stock of caps that you will have to sit on for a long time or possibly forever. I do the same thing on fonts styles for names. Some of the fonts the customers want just don't work for vinyl cuts or embroidery.

FF you will find that younger guys like Flex fit caps. All caps are not friendly to your particular machine so you will have to see by trial and error which your machine sews out best. I haven't run into too many my Barudan won't sew, however, I've heard thru the years others complain about caps not running well on theirs. I don't mind running them at all, but others seem to struggle??? You'll want a design that was digitized from the center out as that will produce less problems for you with registration and such. Most designs have to fall less than 2.4" high to work correctly. Also, right now the flat brim caps are popular with the younger crowd too. You'll want to look for a 6 panel structured cap for the most part.
HTH

I get a lot of orders for the port authority hats from SanMar even though I offer hats from anywhere, including Otto.  The PA hats are a nice structured 6 panel hat with a buckle in the back.  I am finding a lot of people don't like the Velcro because it pulls their hair.  Otto cap has a great selection of hats.  SanMar sells some flexfit including the flat brim ones.  And Tory is right on the size of the design, you are very limited on hats, this is why we offer embroidery on the back as well.  On my old machine I offered side embroidery also, but on my new machine the brim hits the side so it's not possible.

HTH

Tracee

new era hats is the new thing. i have done a lot of them since january. young and old love them!