Front Panel Decoration Size Chart
Front Panel Decoration Size Chart
Choosing the correct embroidery or heat transfer area is essential for optimal design placement and performance. Use this chart as your go-to reference for the most common OTTO Cap headwear and accessory styles.
Headwear and Accessory Styles
| Style | Recommended Decoration Area | Notes |
|---|---|---|
| 5 Panel Foam Front High Crown Styles | Embroidery Not Recommended / Heat Transfer 4.5” W x 2.5” H | Foam front is ideal for heat transfers |
| 5 Panel Low Profile Styles | 5” W x 2.25” H | — |
| 5 Panel Mid Profile Styles | 5” W x 2.5” H | — |
| 6 Panel Low Profile Styles | 5” W x 2.25” H | — |
| 6 Panel Mid Profile Styles | 5” W x 2.5” H | — |
| 7 Panel Mid Profile | 5” W x 2.25” H | — |
| Beanie Styles | 4.5” W x 2.5” H | — |
| Beanie (Reversible) Style No. 91-1234 | Embroidery Not Recommended / Heat Transfer 4.5” W x 2.5” H | Best decorated via heat transfer |
| Biker Style Head Wrap Style No. 98-593 | Front: 2” W x 2” H Back: 2” W x 1.5” H Sides: 4” W x 2” H |
Multi-location options |
| Bucket Hat (Washed Pigment Dyed) Style No. 16-200 | 4.5” W x 2” H | — |
| Camper Cap Styles | 4” W x 1.5” H | — |
| Hat Band | 4.5” W x 1” H | For narrow designs |
| Military Styles | 4.5” W x 1.25” H | — |
| Painter Cap | 4.75” W x 2.25” H | Slightly larger area |
| Running Cap Style No. 133-1047 | Embroidery Not Recommended / Heat Transfer 3.5” W x 2” H | Light materials; decor by transfer only |
| Running Cap Style No. 133-1252 | 4” W x 1.5” H | — |
| Sun Visor Styles | 4.5” W x 1.25” H | — |
Young Adult Headwear Styles
| Style | Decoration Area |
|---|---|
| 5 Panel Foam Front High Crown | Embroidery Not Recommended / Heat Transfer 4” W x 2.25” H |
| 6 Panel Low Profile | 4.5” W x 2.125” H |
| 6 Panel Mid Profile | 4.5” W x 2.25” H |
| Sun Visor | 4.25” W x 1.125” H |
Embroidered, Printed & Designed Headwear Styles
| Style/Number | Decoration Area |
|---|---|
| 114-815 (Reflective Piping) | Top 3" W x Bottom 4" W x 2.25" H |
| 19-701 (Piping Design) | Top 3" W x Bottom 4" W x 2.25" H |
| 57-174 (U.S. Flag Pattern) | 2.75” W x 2.25” H |
| 58-755 (Flag Flame Pattern) | Top 4” W x Bottom 3” W x 2.25” H |
| 80-585 (Flag Design) | Top 4” W x Bottom 4.5” W x 2.25” H |
| 87-478 (Flame Pattern) | 3” W x 2.25” H |
Mask Logo Sizes
| Style | Heat Transfer Area |
|---|---|
| 174-1308 | 4.5” W x 2.5” H |
| 174-1309 | 4.5” W x 2” H |
| 174-1310 | 4.5” W x 2” H |
Standard Patch Sizes
| Shape | Approximate Patch Sizes |
|---|---|
| Square A | 2” W x 2” H |
| Square B | 2.25” W x 2.25” H |
| Square C | 2.5” W x 2.5” H |
| Rectangle A | 3” W x 2” H |
| Rectangle B | 4” W x 2” H |
| Circle A | 2” W x 2” H |
| Circle B | 2.25” W x 2.25” H |
| Circle C | 2.5” W x 2.5” H |
| Oval A | 2.5” W x 2.5” H |
| Oval B | 2.5” W x 2.5” H |
Patch Size Calculation:
To determine your patch size, add the width (W) and the height (H), then divide by 2.
Example: 4” W + 2” H = 6” ÷ 2 = 3”
Tips & Recommendations:
- Areas marked “Embroidery Not Recommended” are best suited for heat transfer decoration due to material or construction.
- For custom sizing or specialty applications, consult the OTTO CAP team for recommendations specific to your chosen style.
- Allow for slight variance per style based on construction and fabric stretch.