Case Study: Custom Plus Size Competition Swimsuits for a Public School District in Portugal
Source:Plus Size Competition Swimsuits /
Time:2026-09-18
Plus Size Competition Swimsuits for a Public School District in Portugal
A Public School District approached us with a plus size competition swimsuits 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
- No reliable way to track a order once it enters production
What we specified
| Product | Plus Size Competition Swimsuits |
|---|---|
| Client type | A Public School District |
| Market | Portugal |
| Order volume | 3,000 pieces across 2 colourways |
| Base fabric | Bamboo Viscose |
| Decoration | Glow-in-the-Dark Printing |
| Size range | S-4XL |
| Sampling rounds | 4 |
| Delivery window | 5 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Bamboo Viscose and locked shrinkage allowance before grading.
- Decoration was moved to Glow-in-the-Dark Printing 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
- 3,000 pieces delivered inside the 5-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
Approve a pre-production sample from the actual bulk fabric. Proto cloth behaves differently in cutting and washing.
Planning something similar?
Book a 20-minute call with our merchandising team and get a written quotation within 48 hours.
