Case Study: Custom Kids Aviator Hat for a Shopify DTC Brand in Denmark
Source:Kids Aviator Hat /
Time:2026-09-18
Kids Aviator Hat for a Shopify DTC Brand in Denmark
A Shopify DTC Brand approached us with a kids aviator hat requirement for Denmark. 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
- No reliable way to track a order once it enters production
- Unclear responsibility when a defect shows up after washing
What we specified
| Product | Kids Aviator Hat |
|---|---|
| Client type | A Shopify DTC Brand |
| Market | Denmark |
| Order volume | 5,000 pieces across 2 colourways |
| Base fabric | Flame-Retardant Fabric |
| Decoration | Piece Dyeing |
| Size range | S-4XL |
| Sampling rounds | 2 |
| Delivery window | 8 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Flame-Retardant Fabric and locked shrinkage allowance before grading.
- Decoration was moved to Piece Dyeing 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
- 5,000 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 1.5%.
- The specification is now on file, so reorders reproduce the approved sample.
What we would repeat
Fix the size ratio early. Changing the ratio after cutting starts is the single most expensive change a client can request.
Planning something similar?
Share a reference photo or a sample garment and we will reverse-engineer the specification for your own label.
