I have made a ton of embroidered hats over the years, they make great personalized present. Here are a few that are still lying around the house.
Begin by designing a graphic keeping in mind who will be wearing the hat. Draw the graphic on a piece paper the same size to fit the hat. Next pin it on the hat wherever seems fit and start sewing over the design. The hole punctures made while sewing weakens the paper so it pops right off when sewing is complete. It's easy and takes only a few hours depending on the detail of the graphic.
You can buy blank hats online or I bought a bunch at Walgreens. I recommend trying the fit of the hat before you purchase. The ones at Walgreens seem to fit both men and women really well.
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