I used Aces High for a while (google them). They're out of Ohio, the ladies name there is Kelly I believe. She's super helpful and nice. Plus their prices are pretty good.
First time I had ever made my own designs with Illustrator and submitted them, emails and calls went directly to owner and he was very very helpful. Eventually went back and had some great embroidered flexfit hats made. Loved the whole experience and will definitely return next time I need printing.