When stitching unsupported, separate letters on knit caps, always use cutaway stabilizer, and don’t cut between letters. When the hat is stretched to fit, letters can often look crooked, seem to be leaning, or look overly spaced due to the stretch and distortion. Leaving the stabilizer in place locks separate elements together.
No matter if you are stitching a light knit, a heavy cap, or even a hand-crafted sweater, just remember to think of the garment structurally and take care of those common problems of stability and texture. You’ll find that you can successfully embroider on even the thickest and most textured substrates and that your thin pieces can keep their shape when properly handled.