I was thinking about a hat hoop, but the price wasn't worth the amount I would use it. I simply made the design with two layers of stabilizer, one tear away and one regular. I used the machine to go around the edges with a satin stitch.
Do you already have the design digitized? The software is really expensive if you don't already have it. I have not perfected digitizing yet and there is a knack to it.
I hope you are able to get it done, that would be a wonderful thing to do for your husband.