I have been embroidering on Flexfit caps for some time now and have not encountered any major problems. I recently sold some athletic mesh caps to a customer and when I started to embroider them I had all kinds of thread breaks. I am using the same logo that I have used on other caps for this customer and had no problems before. I have tried everything I can think of. Anyone got any ideas?
Yes I have changed needles, took the mesh cap out and put a regular flexfit cap in with the same design, it went I was able to sew it with no problem. It seems to be the problem is just with the mesh cap.
My Barudan doesn't like certain types of caps and certain brands of caps and gives me all kinds of trouble when I use those types and/or brands.
So it may be your machine doesn't like something about that cap.
Maybe try a different brand of mesh cap, see if that's the problem.
Are you using a tear away backing on the hats? (maybe try a thicker one) Is your design sewing middle out? (I am guessing yes) I have sew mesh/cool-dri hats from Flex-fit and had no problems besides the fine embroidery taking on the texture of the hat in places it falls in between the mesh... My only other suggestion would be slow your machine down a little bit... Just curious, is it breaking in a fill or satin stitch?
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This Design is all text and is mostly satin stitch, seems to be breaking more on the finer detail. I am sewing at 700 spm. and am using tear away backing. Thanks for your help.
How To Embroider Caps
This is an article Jimmy Lamb wrote for Impressions Magazine in March.
Toward the end of the article he talks about thread breaks.
Maybe this info will help you with your problem.
How To Embroider Caps
This is an article Jimmy Lamb wrote for Impressions Magazine in March.
Toward the end of the article he talks about thread breaks.
Athletic mesh caps 
