I keep having my needle break when sewing on constructed caps. Is this common? Any suggestions? Constructed caps seem to be harder to sew on than unconstructed caps...
1) Try to decrease the stitch density or increase the minimum stitch length. In some digitizing softwares, you can also apply a "cap" style, which adjusts some common parameters for cap embroidery.
2) Or lower you stitching speed
3) try the stitching the design first on a regular flat fabric, and see if you still get those thread breaks
4) You can also check and clean the rotary hook, and adjust the tension of the underthread
5) when all else fails, contact your technician and see if you need to adjust the timing of the machine
I just discovered that for some reason my needles are getting thrown off and slamming into the metal which is causing the needles to break. Any suggestions on why that may be? I was able to sew on an unconstructed non-profile hat just fine. Please help...
Your needle is not clearing the hat when it comes up and then starts it's way down, it gets caught in the hat and and the minor movement in the design is snaping the needle. drives you crazy huh?. Try pushing down on the hat down before you start sewing, sometimes you can get the design started and you'll be OK, you may also adjust your presser foot a little lower to push the hat down before the needle starts sewing or you could choose not to do structured hats they're not worth the trouble sometimes
All good suggestions. I agree that slowing down to 500 spm is proably the biggest help. We are picky about whose constructed caps we use. Some just do not seem to fit our forms as well. Try a different cap style and you may see better results. We also apply pressure from below by holding the back edges of the cap and pulling down before we close the hat device. By the way, be sure to open the back of the cap if it has a buckle or strap. This can help it lay flat.
I am still having trouble. I can sew the logo which is right on the seem but when I go to sew the company name below the logo the needle breaks on the first stitch every time. I've tried all of the suggestions and I still get the same results. I think it's the hat. Have ya'll ever had to refuse to do a certain type of hat before?
YES! It's best to keep a list of styles that fit your frames & try to promote those.
Have you tried starting the design further away from the brim (raising it on the hat)? Be carefull if its a "tall" design or you may create other problems.
Raise the logo up a little bit. On the SWF the hat frame as about a 2" plate on it to hold the hat flat. When we go below that I can hear the needle deflecting.
Also, when you frame the cap, flatten the front of the cap by pulling the bill back toward the top of the cap and bending it straight if it is curved.
Go to a bigger needle. You didn't say what size you were using. Did you get the 12/80 sharp titanium coated?
If all else fails, outsource the the job to another embroiderer so you can keep your customer.
Try changing your sewing order and stitch the wording on the bottom first. I always start at the bottom and work my way up to keep the hat/stabilizer from buckling at the bottom when I am putting a thick logo in the center. I always use 75/11 rp needles unless I am doing 3d I use sharps.
Well I ended up just out sourcing the job and they we're able to sew out the hats. They did said that the type of hats were the worst that they've ever worked with.
Needle breaks on constructed caps... 
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