So you are not crazy and stop pulling your hair out.
If you have a design that has been digitized to sew on a cap, you may see that each time you press start on your machine, you get a different reaction. Sometimes it may sew just fine, and other times you may get a needle break. There are so many variables to work through and your inner detective may need to come out. This is very frustrating when you are in the middle of an order and worried your needle supply is dwindling. The picture above shows a structured cap and I am pointing to the root of a lot of problems. The middle seam on a six panel structured cap can be quite thick. Depending on the design you are stitching, the results of your sew out can vary.