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Cap with big square embroidery logo

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Hi Everyone!

Im just looking for some advice, I do a lot of cap work and have a customer who really wants the DSquared style big square embroidery logo. Just wondering how you would recommend doing this? I have trying making a patch and sewing this on like an applique but the stitching to tack it down doesn’t line up? Are these made flat before the caps are put together? 

This is an example of what type of outcome I’m looking for... in our Embroidery gallery

Thanks in advance

Baseball cap with embroidery design

Kevin

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