Embroidering hats

I found doing a YouTube search helped a lot. Make sure you get the hat nice and snug on the frame by pulling the bottom of the hat while clipping on the front positioning band. Then make sure you clamp the hat to the bottom two bars. I found that on my Tajima I can safely do a 2" logo on the crown of the hat. Any larger and the hat may pop off the machine. So, keep the logo only about two inches tall and make sure you use stabilizer. I use tear away style. I also don't have my machine running at a high speed. I also use poly thread.

I do a lot of flexfit hats on my Toyota 850 I use a double layer of tearaway stabilizer, poly thread and run the machine no faster than 550spm. I can get away with up to 2 1/4 on this machine, depending on the design and the hat style. and yes always keep the hat tight when you put it on the frame. the clips on the bars at the bottom, I find are only needed if I do the flat brim hat. the curve brim hats don't need it, unless, I stitch a very wide design.

Can you describe the problem you are having?

All flexfits are now structured so they have a tendency to not lay flat when hooped. You only need 1 tearaway backing, lower your speed and make sure your designs sew from the center out. I have Tajimas and can sew up to 2.4" when needed but prefer 2.3" or less. I don't know what hoops you use, I have 270 hoops and they do pretty good.