Case Study: Custom Kids Aviator Hat for an Independent Boutique Brand in Portugal
Source:Kids Aviator Hat /
Time:2026-09-18
Kids Aviator Hat for an Independent Boutique Brand in Portugal
An Independent Boutique Brand approached us with a kids aviator hat requirement for Portugal. The brief was specific: a defined look, a hard launch date and a unit cost that had to survive shipping and duty. This case study records what was specified, what went wrong in sampling and how the bulk order was delivered.
The challenge
- Packaging that arrives crushed and unsellable
- Color drift between lab dips and bulk fabric
- Minimum order quantities far above what a growing brand can absorb
What we specified
| Product | Kids Aviator Hat |
|---|---|
| Client type | An Independent Boutique Brand |
| Market | Portugal |
| Order volume | 1,200 pieces across 2 colourways |
| Base fabric | Crepe |
| Decoration | Sequin Work |
| Size range | S-4XL |
| Sampling rounds | 4 |
| Delivery window | 8 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Crepe and locked shrinkage allowance before grading.
- Decoration was moved to Sequin Work after strike-off tests showed better wash durability.
- A pre-production sample was approved and retained as the golden reference.
- Production ran with in-line inspection and a mid-run photo report.
- Cartons were packed to the client's own barcode and size ratio specification.
Result
- 1,200 pieces delivered inside the 8-week window.
- Unit cost held within 2.0% of the original quotation.
- Return rate linked to fit or workmanship stayed under 0.5%.
- The specification is now on file, so reorders reproduce the approved sample.
What we would repeat
Lock the colour standard before grading. Once a shade moves, every downstream approval has to be redone and the calendar slips.
Planning something similar?
Send us your tech pack or even a rough sketch — we will come back with fabric options, a costed sample plan and a realistic production calendar.
