NeedleUp Digitizing ~~~~~~~Stitches and Stats
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TEXT:

.24" is generally the smallest text that will sew cleanly (cap 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

 
STITCH ESTIMATOR

Square Fills

Density
3.5 / 4.0
1400 / 1300 = 1"
5200 / 4700 = 2"
11300 / 10250 = 3"

Circle Fills
3.5 / 4.0
1200 / 1050 = 1"
4200 / 3800 = 2"
9000 / 8200 = 3"

Satin Stitches 1" = 175 stitches
Walk Stitches 1" = 20 stitches

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