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Need help with patches on hats

Need some help. I am pre making patches in a flat hoop. My hope was to take the patch and apply it to a hat on my brother pr1000 cap frame. The issue is that the tack down stitch is smaller on the length and looks awful. I assume because I am using the flat patch size for the tack down on a curved surface. How do i reconcile this. I want to tack down just inside the satin border of the patch or satin border around the patch to attach it.

I am using wilcom hatch 2 software on a pr1000.

Thanks in advance.
 
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