• 678-431-1467
  • This email address is being protected from spambots. You need JavaScript enabled to view it.
  • Mon - Fri 9am - 5pm EST

Stitching on hard structured, buckram caps

Richardson 112We receive a lot of complaints and concerns about hard structured caps including The Infamous Richardson 112 and similar model caps. These hats are great looking caps that have a front that hold its shape like a batter’s helmet. They hold their shape, however; the thick hard buckram in the front is so hard it ends up shredding thread and breaks needles. Customers love them and embroiders hate them.

Click Read More for a few things that you can do that may help when embroidering these caps.



Use a combination of these hints and ideas to aid in stitching your caps.

  • Hoop your cap tight and make sure that you get rid of as much of the space as you can between the cap and needle plate. The moving cap surface flexes the needle and this pulls the needle over to the edge of the needle plate hole. This is what breaks your needle.

  • Several layers of backing may help with the stitching. This may create a ramping effect that may help with needle breaks.

  • I have some customers that heat press the cap before they stitch it. This softens the plastic backing so it doesn’t shred the thread as much.

  • You may want to steam the cap just before stitching
  • Try a heat gun.
  • Saturate the front panels with water from a spray bottle.




Some embroidery machines come with a flat needle plate and a cap needle plate. The plates were changed out as needed when setting up for flats or caps. Some of these machines changed over to a universal needle plate which worked with either setup.


Look at the images to the right:




Flat needle plate.

Some embroidery machines come with a changeable BOSS. You can change the boss for flats caps or universal.


See Below:


Cap needle plate.


Needle plate with Boss insert.




Needle plate boss


Universal needle plate.