How To Embroider A Cap From Start To Finish On The Melco SUMMIT

Embroidering hats may seem intimidating, but with the right tools and technique, it’s a smooth process. In this guide, you’ll learn how to hoop, prep, and embroider structured and unstructured hats using the Melco SUMMIT—so you can take your projects from failed it to nailed it. Watch the full video tutorial on our YouTube channel.

cap-embroidery-melco1

Step 1: Install The Cap Gauge

  1. Open your clamp.
  2. Place the cap gauge on the table and secure the clamp by screwing it shut.

Step 2: Prepare Backing

  1. For structured caps, use one piece of cap backing.
  2. For unstructured caps, use two pieces for extra support.
cap-hoop-

Step 3: Understanding Cap Frame Components

  1. Left side: Two wing nuts for adjusting tension
  2. Back: Two black posts for securing clips
  3. Right side: Strap latch
Cap tab alignment example
Cap strap teeth alignment

Step 4: Hooping The Hat

  1. Lock the cap hoop into the cap gauge.
  2. Swing the strap latch open to the side.
  3. Roll your cap backing so it curves naturally and place it in the hoop.
  4. Prepare your cap:
    • Remove any cardboard.
    • Pull out the sweatband.
  5. Slide the cap and backing onto the hoop so the bill sits flush with the tab.
  6. Walk the strap teeth into the seam between the crown and the bill.
  7. Rotate the strap latch into its notch but don’t close it yet.

Step 5: Adjust Strap Tension

  1. Loosen the two wing nuts.
  2. Press the strap for a snug fit.
  3. Retighten the wing nuts. (Adjust for each new hat style.)

Step 6: Final Hoop Checks

  1. Rotate back into place (with cap bill facing upwards) and close the latch.
  2. Remove the hooped cap and ensure the strap is level for accurate stitching.
  3. For unstructured hats: Gently tighten the fabric and use clips on the black posts for stability.

Step 7: Install Cap Driver

  1. Remove both hoop arms.
  2. Loosen and remove the hook guard.
  3. Insert the lower support arm under the cylinder arm (ensure screws are flush with the top of the T-nut). Slide until it will not go any further back.
  4. Finger-tighten, then reinstall the hook guard.
  5. Finally, apply a drop of oil to the lower support arm.

Step 8: Adjust Cap Driver Height

  1. Mount the hat driver and secure it with two screws in the innermost holes.
  2. Use two business cards to check driver height (gap between driver and needle plate).
  3. Adjust the cap driver height if needed, using the 4mm Allen driver (included in your Melco machine operator’s kit) to make any adjustments.
  4. Loosen screws slightly, then go back and tighten in a crisscross pattern.
  5. The business cards should be snug enough to slide easily between the bottom of the hat driver and the top of the needle plate.

Tip: Label your cap driver with the machine name or serial number if using multiple machines.

Step 9: Loading A Hat Onto The Machine

  1. Turn the cap sideways to fit it behind the needle case.
  2. Rotate the cap upright until it “clicks” into place.
  3. Engage all three clips.

Step 10: Setting Up Your Design On The SUMMIT – Best Settings For Caps

  1. Open the Hoop Selection Screen using the button on the left side of the touchscreen.
  2. Select the hat driver icon, then choose WACF (Wide Angle Cap Frame). (See photo 1)
  3. Slow your sew speed to 900 SPM.
  4. Flip your design 180° (since the bill faces away from you).
  5. Make sure your design stitches from the center out for best results.
  6. Adjust Acti-Feed settings: (See photo 2)
    • Thick hat: set to 10–12
    • Thin hat: set to 5–6
    • Average: set to 7
  7. Adjust Presser Foot Height:
    • Average: 3–4 clicks up from the bottom.
    • Adjust higher or lower based on hat thickness.

Step 11: Position & Trace Your Design

  1. Use the arrow keys on the touchscreen to move the design about ½ inch above the bill.
  2. Using the left/right arrow keys, align the active needle to the center seam of your hat.
  3. Click Trace to check placement and make fine adjustments if needed.

Step 12: Get Stitching!

Now that all your prep work is complete, it’s time to start stitching your design. On the Melco SUMMIT, simply hit the start button to begin sewing.

How To Embroider On A Cap: Full Video Tutorial

Check out the video below for a complete tutorial on embroidering caps with your commercial machine. Learn the techniques and gain the confidence to stitch hats like a pro.