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How to Prepare Your Logo for Cap Printing and Embroidery

By Sonam S. June 28, 2026 19 Views No comments

Most cap problems start with the logo file, not the printer. Fix the file first and the proof usually looks right.

Vector vs raster

A vector file stores shapes as lines and curves, so it scales without blur. A raster file (JPG, PNG) is made of pixels and gets soft when enlarged. Vector is the safest choice for both printing and embroidery, because embroidery needs clean outlines to convert into stitches.

PDF, AI and EPS, and when raster may be acceptable

PDF, AI and EPS are common vector formats. PrintOnline's cap pages do not list accepted formats; its ribbon page asks for "a vector PDF, AI or EPS file where possible", so send those and confirm. A high-resolution raster may be acceptable for printed artwork with solid shapes, but embroidery usually needs a redraw. Ask before assuming.

Why small text and thin strokes fail in embroidery

Thread has thickness, so tiny letters close up and hairlines disappear. Printing has limits too: the caps page says "Small & Thin Shapes or Text can't be printed". See printing vs embroidery.

Simplify without changing your brand

Remove taglines under the logo, or use them only on a poster.
Thicken thin outlines.
Reduce gradients to flat colours.
Keep the symbol and name, in the same proportions.
Some options limit colours: the 3D embroidery page says one colour only, and the personalized cap page says spot colours for embroidery.

Print areas

The maximum front print area is 9 x 5 cm. That is the number to design to, and it is smaller than most people picture: about the size of a credit card laid on its side.

Decoration is sold by "spot": 1 spot (front only), 2 spots (front plus back, or front plus one side), or a 1 spot 3D plus 1 spot normal combination. Maximum areas for the side and back positions are not published, so ask for them if you are placing a mark there.

Lay your logo into a 9 x 5 cm box before you send it. If the tagline stops being readable at that size, it should not be on the cap.

Good and unsuitable artwork

Good: a bold wordmark, a simple symbol, two or three flat colours, thick strokes. Unsuitable: a full-colour photo on embroidery, a logo with a tagline in tiny letters, thin outlines, a faint gradient. Test any design at its real size on screen before sending.

Confirm colours, placement and proof

State the cap colour code, the logo colours, and where each mark goes (front, side, back). Production starts from the mockup you approve, and the delivery calculator allows 1 working day for file preparation and mockup approval. PrintOnline's terms say each item is produced "to the proof you approve", so check spelling and placement carefully. Do not rely on screen colour as an exact match.

Design assistance

The cap page offers a free design consultation and a self-design option on Canva.

Upload your logo on PrintOnline's caps page.