For a typical left or right chest embroidery, the ideal design has a maximum dimension of 3.5" - 4.0". There are exceptions when a design has one dimension that is several times larger than the other. The size of many designs is dictated by the smallest text in the design. We will size your design appropriately based on our experience. The smallest text we can embroider with any accuracy is about 0.20" (5mm) high. We can make adjustments to your design to compensate for slight variations. Typically, a single line of text can only include about 20 characters and spaces before it requires the text to be split into two lines. The maximum height for a head wear design is 2.25" high (less for visors). The width may be as wide as 5" or even more. Embroidery on the side of a cap may be included at no additional cost other than charges for more than 10,000 stitches.