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

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 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 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

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 Heat Transfer

Digital print heat transfer is applied with 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. 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 / 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 Heat Transfer

Vinyl applique heat transfer is great for logos to have a single bright, bold or special effects color.

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 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. In stock color options: Bright Gold, Rose Gold, Bright Silver, Yellow Gold, Halo Rainbow Silver, Sapphire Blue, Red, Silver Scales, Light Rose, Amethyst, Pink, Copper, Teal, Kiwi, Green, Orange, Coral, Maroon, and Black. Additional colors available with advance notice.

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 (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 x Height < 3 sq. inch. For more sizing information and options, please check the size chart below.

* Works great on 6 panel & 5 panel caps.

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 x Height < 3 sq. inch. For more sizing information and options, please check the size chart below.

* Works great on 6 panel & 5 panel caps.

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 x Height < 3 sq. inch. For more sizing information and options, please check the size chart below.

* Works great on 6 panel & 5 panel caps.

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 x Height < 3 sq. inch. For more sizing information and options, please check the size chart below.

* Works great on 6 panel & 5 panel caps.

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 x Height < 3 sq. inch. For more sizing information and options, please check the size chart below.

* Works great on 6 panel & 5 panel caps.

Faux Leather Deboss Patch (3 inch max.)

File Type

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

Maximum Colors

Choice of Light Brown / Dark Brown / Black

Maximum Size

Width x Height < 3 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 (3 inch max.)

File Type

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

Maximum Colors

4 colors

Maximum Size

Width x Height < 3 sq. inch. For more sizing information and options, please check the size chart below.

* Works great on 6 panel & 5 panel caps.