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What if the hat was floppy enough to stretch the front out flat? Unstructured? Or would that still not work?

And I'm only hoping to have about a 3"x4" logo done.
a procedure like this you'll have to go with big manufactures that does hats and have chenille machines overseas. you'll have to purchase over 150 units. this isn't an easy task as you think. you can't just stretch the front of the hat flat. even if you do that 1 perfect hat.. you have to be consistent with production.
 

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This would pretty much have to be done on bulk fabric and then cut and sewn. I have never seen chenille on a hat, direct or otherwise.
 
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