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Needle Breaks On Caps – Errors, Tips, And Solutions

Caps are unique. In the digitizing industry, they have their importance in the eyes of a digitizer. It is interesting to make embroidery designs on caps. You have the tools to perform stitches around curved caps like the special cap hoops, and clips to hold things. 

The machine that you use can vary. You may have a newer or an older version of the embroidery machine for your cap, but the process for cap logo digitizing remains the same. We, at 360 Digitizing, have been offering embroidery digitizing services of all kinds to our customers for decades. We know the ins and outs of cap logo digitizing.   

In this article, we talk about the needle breaks in caps. What are the causes of needle breaks? In what situations do needle break occur? What are the preventions and solutions? And what can you do to cater to the situation? 

You need to keep in mind that you will come across different kinds of errors during the embroidery digitizing process. However, you should not worry about the problems. If you are familiar with the basics of the digitizing industry, you can handle every problem in accordance with the situation. 

Why Is It Hard To Make Stitches On Caps?

To start off, needle breaking on caps is a more common problem than having needle breaks at flats. The reason behind this is that you have to stitch on a curved surface. It is difficult to make stitches on caps. Caps are harder for needles to penetrate. The theme on the needle increases the chances of it to break. Conversely, on the flats, the situation is different. It is easier to make stitches on a flat surface.

In these situations, you may think that your embroidery machine is having an issue, but it is not the case every time. The problem is very common and trivial to the digitizers when they are performing stitches on caps. 

At this moment, the question that may arise in your mind is, what can I do then.  Well, to solve a problem, first you must know how it works. Large organizations or big companies modify their needles quite often to avoid needle breaking on caps. These companies make amazing designs on caps. And what creates interest is that they do it on a large scale in a smooth way. 

You may ask yourself, ‘how do they do it?’ Well, the answer is simple. They make these designs on slide/flat machines. The process to assemble the caps is done afterward. This strategy gives the digitizing companies a huge advantage. They can make any embroidery design or artwork at ease. Be it simple or complex, on a flat surface, the process becomes easier. 

Now comes the big question. What to do if the cap is already assembled? Can you do the same embroidery work on it? The answer is a big yes. You can make any design you want on embroidery machine. You need to follow some rules to be successful in achieving your goal. 

Keep in mind that not all the caps are easy to stitch. At times, you will find some caps that are harder than the other ones. It is because of the material of the cap. Secondly, the complicity of the logo or the artwork matters a lot. The more complex the logo is, the harder it is to make a stitch on a cap. 

Tips To Prevent Needle Breaks

This would have given you all the required information about the needle breaks. Now, we will share some tips with you on how to avoid the needle breaks. It will help a lot when you perform embroidery digitizing on caps. 

Use Sharp Needle Point

Before troubleshooting any other problem, check your needle. Yes, this is the first and essential tip we can give you. If you are a novice, it will be agonizing to make clean and perfect stitches. But, there is no need to panic. 

To make ideal and flawless stitches, we recommend you to use an 80/12 sharp needle. We suggest this to do so because bold points are more favourable to break on caps than sharp points. So, to get the finest outcome, it is highly recommended to use a sharp point to avoid needle breaking on caps. 

The Design 

The design that you want to put on your cap means a lot to the digitizers. When it comes to cap logo digitizing, it is important to know that the process of digitizing is a bit different. Sometimes it becomes hard to get the exact design that you have on your shirt, jacket, pants, or any other flat surface. 

However, it is not the case every time. It is possible to have the exact design on your caps. But usually, it is difficult to do so. It is a smart step to simplify your design or logo. It will make the process much easier for you. To get things done, you need to know the digitizing rule for caps. 

The rules are simple. You need to digitize from the inside to the outside of your cap. It is not necessary to follow the rule, but we recommend you to follow it if you are new to the industry. However, one thing that you should go along within the entire process is to simplify your design. You can do this by reducing overlay and reducing some lock stitches. You can also add a pull compensation to the logo. 

These minor changes will make a huge difference to make the exact stitches that you want. It will be easy for you to make stitches on the cap. 

Hoop Properly

It is essential to hoop properly to get perfect stitches on a cap. The way you hoop will define the quality of the design of your cap. Half of the quality of your embroidery designs depends on the way you hoop. It implies to both flats and caps.

To hoop properly, you need to practice. You may have heard that ‘It takes 10,000 hours to master a skill.’ So, the more time you give, the easier it gets to hoop in a smooth way. 

Bonus Tip:

One bonus tip we can give you is to stretch the cap very tightly. It will help you in the long run. 

The Gap

Another thing that you need to jot down to avoid needle breaks on a cap is the gap between the cap and the needle plate. The gap can create a problem. It will be a hindrance to you to make stitches on your cap. If there is a gap between the cap and the needle plate, you are going to have needle breaks. 

To avoid the situation, you have an extra needle plate with the red line that can be raised. It will help you to eliminate the gap between the needle plate and the cap. The companies often modify their machines to avoid this gap. They put the washer to reduce the gap between the cap and the needle. 

Another thing that you can do is to put the clips that are available to the bottom of the cap. It will also help in reducing the gap between the cap and the needle plate. You can also press the cap with an iron. If you don’t have the iron to press, you can also use a heat press. It will help you to reduce the gap. 

Don’t Stitch Close To The Bill 

It is also an essential factor. You need to be attentive when you stitch on caps to avoid needle breaks. You don’t have to stitch close to the bill. It is recommended to leave at least half an inch between the logo and the bill of the cap. The reason to leave the space is because of the needle break. The closer you stitch to the bill, the more chances are to have needle breaks. 

Bonus Tip:

One bonus tip we can give you is not to exceed your logo more than two inches in height. It will help you a lot. It makes the design look more charming and fascinating.  

Bottom Line

To sum up, we recommend you to get yourself familiar with the process. Know all the differences and similarities of embroidery machines, software, and tools you will need to use to make designs on caps. Dip deeper and try to learn as much as you can. 

It is imperative to have problems when you are making stitches, but if you know the process, you can solve the needle break issues with ease. Practice on how to hoop properly. Use sharp needles. Get yourself with the designs. Don’t stitch close to the bill. These tips will help you in the long run. 

If you need any further help or you are facing any needle break issue, feel free to contact us. 360 Digitizing has a customer support team that is ready to help its customers 24/7. Our customer support representatives will be happy to assist you.

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