At that time, we worked with the manufacturers, so the cap peak and crown were sent to us before they were constructed. Many years ago, baseball hats were manufactured in North America sadly, this is no longer the case. Second is, this design was done as a panel program. So please take my advice and “DO NOT” try this at home… your machine may not survive! The reason why is, when you put 6mm of a foreign substance under the needle of a machine, it sounds like a rocket ship taking off to the moon. Two other things I’d like to mention about the process. When the design was finished on the machine that was all you saw, and when the foam was torn off the entire dog appeared… embroidery magic! The eyes are set back right onto the surface material of the hat, then building it up 2mm, then 4mm, and finally up to 6mm which is just the dog’s jowls, brows, and top of his ears. The reason why? I used three pieces of 2mm foam and built up the design dimensionally. ![]() ![]() It’s hard to believe that I digitized that design over 20 years ago! I remember when we ran it on the 24-head Tajima machine it was like embroidery magic when it was done. Watch this fun video showcasing a three-layer foam bulldog cap that won me my first digitizing Grand Prize with EMB Magazine in 1998. In-the-Hoop Projects: Zipper Insertions. ![]()
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