Don't have time to go back and read this whole thread, but I think someone suggested a patch, which would solve this problem of different hat styles. If the Mudcat design was embroidered onto a patch, you could sew that on your jacket, shirt, hat, cap, whatever you want. Direct machine embroidery onto the cap or garment requires that you buy a bunch of the same type of cap or garment. The machines have multiple 'heads' with a quantity of caps or shirts attached to hoops and mounted under the heads, which are all set up with the same thread colors for the design. Then the program with the design runs all the heads on the embroidery machine at once. To set up an order takes time, so it's not something you would want to do for a small quantity. I think getting an embroidered patch would be a great solution. I can check on price if you want me to.