Part 1: The “Seam” Barrier

Explain that hoops work by clamping fabric between two rings, like a drum.

• The Physics: The fabric must be perfectly flat inside the hoop.
• The Rule: We cannot sew directly over thick seams, heavy zippers, or shirt pockets.
• Clearance: Always leave at least 1 inch of clear space away from seams or zippers to allow the hoop to clamp down.

Part 2: The “All-Over” Exception (Cut & Sew)

Clients often point to NBA jerseys with stripes crossing seams and ask, “Why can’t I have that?”.

• The Answer: That is called Cut & Sew (or Sublimation).
• The Process: Those designs are printed on flat fabric BEFORE the shirt is sewn together.
• The Reality: We are embroidering on Finished Garments (off the shelf), so we cannot cross seams. Edge-to-edge designs require custom manufacturing with huge minimums and long lead times.

Part 3: Max Imprint Areas (Standard Hoops)

Just because a shirt is an XXL (26″ wide) does not mean we can sew a 26″ logo. The machine arm must fit inside the hoop.

• Left Chest:
  • Max Sewable Area: 4.0 to 4.25 inches wide.
• Full Back:
  • Max Sewable Area: 10 to 11 inches wide.
  • The Trap: Clients often ask for “14 inches wide”. Explain that going bigger than 11″ requires special “Jumbo Hoops” that cost extra time and money. Quote 10-11″ as standard.

Part 4: Caps (The 2.25″ Rule)

Caps are difficult because the “Bill” (visor) acts as a hard physical wall.

• Height Limit: The maximum height for a standard Cap Front logo is 2.25 inches.
  • Why? If the logo is taller, the machine head will physically hit the bill.
• Width Limit: Typically 4 to 5 inches wide. Any wider, and the logo wraps around the curve, causing distortion.

Part 5: Video Resource

• Watch: How Low Can You Stitch on Hats? (Placement Limits)