You want to buy embroidered hats. You’re wondering how to size your front and back designs when considering why you shouldn’t get your designs the same size as the designs on your favorite hat.
That may work, but not all designs are the same as they are perceived visually. Even if the designs are basically the same shape, a design with a single large element can have a different size than a design with smaller details. Custom hat designs are also limited to a height of 2.25 inches. While your favorite hat may have a 3-inch design because it was embroidered before assembly, your custom design needs to be smaller. Are you afraid that your design will be unreadable if it’s only 2.25 inches tall? Then you need to simplify it or rearrange the different elements within the design so that it fits better in the front area with a width of 4 inches x 2.25 inches.
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