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What size/style needle would recommend for 60 wt thread on a structured hat? As I mentioned we currently use 12/80 titanium sharps with the 40 wt but I'd assume a smaller needle would provide better accuracy, but not so small to cause breaking along the seam.I would suggest that on that small lettering you use a 60 wt thread. I will not be as bulked up as the 40. I also agree with the others, get a professional digitize...![]()