Hi amz...I don't really have any advice for you, but wanted to Welcome you to Cute!! To understand better how the site works...just click on the orange Q&A tab across the top...lots of great information there for newbies to have a better experience here...also if you have not already read the Terms & Conditions (below at the very bottom of the site) you should as our Moderators work very hard every day to help keep our site clean and running smoothly without violating any copyrights...again...Big Welcome!
Welcome to Cute amz :)
I have done face towels for kids (12x12 inch) and I usually do a size that can fit in my 4x4 inch hoop! The font can be 2 inch high and the design can fit in at 2 or 2.5 inches! (Will ofcourse depend on how big or long the name is)
For the hood of the towel you can make the same thing a little bigger, the font can be 3 inch high and the rest according to the space available!
Applique designs are a quick and easy solution for kids towles as compared to filled designs!
You have a brother so any font from the built in ones should work...in my towels mostly I have used script style fonts but any would look good just shouldn't be too narrow or thin that it would get lost in the nap of the towel! Make sure to use a water soluble topping to keep the stitches nicely raised!
Better avoid design which are too dense as it will make the embroidered part very stiff!
Well this is all I can say and if you need any more assistance you can send me a message from your inbox :)
Thank you very much for your help, I will try it and let you know. By the way just seen your work, its amazing.