Hi LuAnn, Hope the cut away solved your problem? Anand Anand, No, I have never used "cut away" when doing caps. I have always used "tear away." Is using cut away the answer? I am so used to the older style with the "wings" that support the cap so well. I will try the two layers of cut away and see what happens. Thanks for the tip. If I continue to have problems I will take you up on your offer to tweak the design though. This run is for a special event, but the yacht is going to use a version of this design for their new logo. And that will mean lots more hats!!! LuAnn @ Image Embroidery =========================================================== =========================================================== The AmayaUsers Mailing List Website: http://www.amayausers.com Discussion Board: http://www.amayausers.com/boards Subscribe/Unsubscribe: http://www.amayausers.com/list ===========================================================