Using the appropriate needle for the job is essential.
This needle bent and broke. It was a 65/9 (small needle) and they were sewing on a structured cap.
Inside a structured cap is buckram. Buckram is a coarse, woven cotton fabric that is stiff. They use it in structured caps.
This heavy fabric will break a small needle.
Use an 80/12 sharp or bigger needle for embroidering on structured caps.