The height rules
Letter height decides how lettering sews
Cap height in millimetres is the one number that matters more than the font. These are the thresholds digitizers work to.
| Cap height | What the plan does | Fonts that hold | Typical use |
|---|---|---|---|
| 3 to 4 mm | Run stitch only; flagged | Plain sans | Care labels, tiny taglines. Expect legibility loss. |
| 5 to 6 mm | Satin with reduced density; flagged at the floor | Plain sans, bold | Taglines under a logo, small names on caps |
| 7 to 10 mm | Standard satin columns with underlay | Sans, serif, varsity; script from 8 mm | Names on polos, caps and beanies |
| 11 to 25 mm | Satin; columns split at 7 mm width; puff possible | All four | Team names, jacket fronts, bold statements |
| 26 to 60 mm | Columns split to fill; stitch counts climb | All four | Jacket backs, banners |