The crown size of the hat is the measurement from the bill of the hat to the top of the hat. Finding this measurement will help you determine the limits of the imprint size. Often, cap manufacturers will specify crown size in their specs. A good rule of thumb is to keep any decoration on the hat about a half inch smaller than the crown size. So, for example, if you have a hat with a crown size of 4″, you’d want to make sure the decoration is no more than 3.5″ high.
—EnMart