Densities, I can not tell you, it depends on a type of a hat. And even if I tell you my settings, it would not help you. I got used working on a metric system and my setting for a slightly increased density is -0.3 or sometimes -0.5. The density for a puff is set to -2.25 of something, I do not even know the name of the measure.
On my Pulse software, if I need more dense design my numbers are getting smaller. When I went on a training at Hirsch, they explain to me how to change it, but I was already used to it, I was getting confused for a few days and I just put it back how it was at the beginning.
But my sew order would be (Lets say 3 letter logo) outline, letter, outline, letter, outline, letter. Just to prevent shifting of the hat.