Patch It Up Pro

Flexfit 6277 Mockup, Specs, and Embroidery Size Guide

Short answer: The Flexfit 6277 Wooly Combed is a structured, six-panel, mid-profile fitted cap with a 3.5-inch crown and Permacurv visor. For front embroidery or a patch, start around 3 to 4 inches wide and 1.75 to 2.25 inches tall, then test the design on both S/M and L/XL blanks.

Quick specifications

Model
Flexfit 6277 Wooly Combed
Profile
Mid
Construction
Structured, six panel
Closure
Closed back / stretch fitted
Sizes
S/M 6 3/4–7 1/4; L/XL 7 1/8–7 5/8; separate 6277XX available
Crown
3.5 inches
Material
63% polyester / 34% cotton / 3% PU spandex
Recommended decoration start
3–4 in wide × 1.75–2.25 in tall

Starting decoration sizes for a Flexfit 6277

Starting decoration sizes for a Flexfit 6277
DecorationStarting sizeProduction note
Front embroidery3.5 × 2 inDigitize for a curved structured crown
Rectangle patch3 × 2 inTest seam and crown tension
Circle patch2.25–2.5 inKeep small text away from the seam
Side embroidery2 × 1 inVerify placement on both fitted sizes

Production recommendations

  • Mock up each size family: A fitted cap changes shape and tension between S/M, L/XL, and XXL. Do not approve a size run from one generic crown.
  • Digitize for structure: Use appropriate underlay and density for the hard buckram front. A file tuned for an unstructured dad cap may not sew the same way.
  • Keep type practical: Small text should be tested at stitch scale, not only viewed on a high-resolution screen.

Frequently asked questions

Is Flexfit 6277 fitted or adjustable?
It is a closed-back stretch-fitted cap. The official product page lists S/M and L/XL, with a separate XXL model.
How tall is the Flexfit 6277 crown?
Flexfit lists a 3.5-inch crown and a mid profile.
What is a safe front embroidery width?
Start around 3.5 inches and validate on the machine and cap frame. Many designs can go wider, but the safe width depends on hoop, digitizing, and cap construction.

Sources