Custom Embroidery Services in Canada
Custom Caps Canada offers flat embroidery, raised 3D puff embroidery and embroidered patches for businesses, clothing brands, teams, events and individual customers. We use commercial Tajima embroidery machines and carefully prepared digitizing files to produce clean stitching, consistent placement and lasting results.
Professional Embroidery for Hats and Apparel
Embroidery can give your design that premium, textured finish, because the thread is stitched right into the item itself. It’s a solid option for custom hats, polos, hoodies, jackets, workwear, uniforms, and branded merchandise.
Before production, our team reviews your artwork, product and preferred placement. We look at letter size, line thickness, stitch count, thread colours, how the fabric is built, and whether your artwork works best as a flat embroidery, a 3D puff option, or a patch.
Some artwork may need tiny adjustments, just to get a cleaner result, like fewer surprises in the final output. We may enlarge small lettering, thicken fine lines or simplify detailed areas that cannot be reproduced clearly with thread.
At Custom Caps Canada, we offer multiple embroidery types you can use to decorate your apparel. With high-quality digitizing and state-of-the-art Tajima machines and experience embroidering over 100,000 products, we provide Canadian Custom Embroidery with tight stitches and clean results.
Manual Embroidery Digitizing
Your artwork has to be transformed into machine instructions that an embroidery machine can read, this is what people call embroidery digitizing.
We manually prepare each design rather than relying on a basic automatic conversion. This allows us to control satin stitches, fill stitches, running stitches, stitch direction, stitch density, underlay, and push and pull compensation.
These settings help text remain readable, borders stay aligned and larger areas stitch smoothly. Common embroidery machine file formats include DST, PES and EXP. We commonly prepare DST files for production on our Tajima embroidery equipment.
Flat Embroidery
Flat embroidery, sometimes called regular embroidery, is stitched directly onto the product to create a clean and professional finish.
It is the most versatile embroidery option and works well for:
- Company logos and uniforms
- Custom embroidered hats
- Polo shirts and jackets
- Hoodies and sweatshirts
- Workwear and team apparel
Satin stitches are commonly used for lettering and borders, while fill stitches cover larger solid areas. Running stitches may be used for outlines and selected details.
For reliable embroidery, we generally recommend lettering at least 6 mm tall and important lines or stitch columns approximately 1–1.5 mm thick. The exact minimum depends on the fabric, font, thread and placement.
Best for:
Logos, uniforms, business apparel and designs with moderate detail.
3D Puff Embroidery
3D puff embroidery creates a raised effect by placing foam beneath the stitching. The thread is stitched over the foam to give lettering and simple shapes a bold, three-dimensional appearance.
It’s especially popular for front logos on structured baseball caps, snapbacks and trucker hats, you know the whole look.
Very small lettering, thin lines, narrow spacing, and detailed artwork are usually not that suited for 3D puff embroidery. Raised areas often need stitch columns around 3 mm to 15 mm wide so the thread can cover and grip the foam properly, otherwise it can get a bit messy and you might notice it later too.
Best for:
Structured caps, streetwear designs and bold sports-style logos.?
Embroidered Patches
Embroidered patches are made separately then attached to a hat, garment or accessory.
They deliver a classic badge style finish and they fit really well for logos, emblems, uniforms, workwear, team clothing and branded merchandise. Our embroidered patches can come with iron-on backing, plus they can be produced in different shapes, sizes, and thread colours.
If your artwork includes very small text or fine detail we might suggest a woven patch instead, depending on what you’re trying to achieve. Woven patches use thinner thread and can reproduce more detailed designs with a flatter finish.
Best for:
Badge-style logos, emblems, uniforms and designs requiring a defined border.
Thread, Backing and Embroidery Placement
Needle type and size are selected based on the fabric, thread weight and design requirements. Caps, polos, jackets and delicate garments may require different needle and stabilizer combinations.
We typically use professional 40-weight embroidery thread, or 40W, for standard logos and apparel. Thread colours can be picked to match your branding closely. Still, an exact Pantone equivalent may not always be possible. Thread has its own texture and sheen, and it can end up looking slightly different once it's actually stitched in place.
Backing or stabilizer is placed behind the fabric to support the stitches and help reduce puckering, shifting and distortion. The backing used depends on the fabric, design size and stitch density.
Flat garments are secured in embroidery hoops, while hats are embroidered using specialized cap frames. Centre seams, curved panels and crown height can affect the maximum logo size and placement.
Our Embroidery Gallery
Explore examples of custom hat embroidery, flat embroidered logos, raised 3D puff designs and embroidered patches produced for businesses, brands, teams and individual customers.
CTA - Ready to Start Your Custom Embroidery Order?
Upload your logo or artwork and tell us what you would like to customize. Our team will review your design, product selection, quantity, embroidery placement and required delivery date.