[amayausers] design on caps

Hi all,
I put together a design for a customer and sometimes the design sews out great 
and at other times the  top of the letters (only  the top word) come out half  
there and some not at all. I don't like wasting hats but husband pushed me to 
do five.
my question is why would the this happen to some and not all? and could part of 
it be that it may have sewed too high on the cap?
Thank you,
Phyllis
Crickets' Creations


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