The medium of embroidery has its limitations. Following these parameters will result in a production friendly, esthetically pleasing design.  Listed here are some guidelines for the creation and layout of effective embroidery.

.24" is generally the smallest text that will sew cleanly (upper case, open block)...there are exceptions to every rule....

You can fit 5-6 1/4" characters in an inch of line space

Arcing text doesn't give you more width space

There is only 1-1.25" height of sewing space on a visor

Cap logo height is about 2.25".....width is usually about 4 - 4.5"

Most left chest size designs are 3" - 4" wide

Cap backs have about 3.5" wide text space and are usually arced for a pleasing appearance

Square fills:                                      Circle fills:

Density
3.5 / 4.0                                          3.5 / 4.0
1400 / 1300 = 1"                               1200 / 1050 = 1"
5200 / 4700 = 2"                               4200 / 3800 = 2"
11300 / 10250 = 3"                            9000 / 8200 = 3"

                           Obviously, the number of stitches it takes to create a letter varies depending on what character it is and the size and font...

At .25", open block lettering, 5 characters of text is usually between 500 & 600 stitches
A 2.5" diameter circle of .25" block text has approx 27 characters