Case Study: Custom Quick Dry Surf Rash Guard for an Independent Fashion Designer in Portugal

Quick Dry Surf Rash Guard for an Independent Fashion Designer in Portugal

An Independent Fashion Designer approached us with a quick dry surf rash guard 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

• Color drift between lab dips and bulk fabric
• Packaging that arrives crushed and unsellable
• Minimum order quantities far above what a growing brand can absorb

What we specified

How it was resolved

1. We rebuilt the tech pack around Recycled Polyester (rPET) and locked shrinkage allowance before grading.
2. Decoration was moved to Smocking after strike-off tests showed better wash durability.
3. A pre-production sample was approved and retained as the golden reference.
4. Production ran with in-line inspection and a mid-run photo report.
5. Cartons were packed to the client's own barcode and size ratio specification.

Result

• 5,000 pieces delivered inside the 10-week window.
• Unit cost held within 3.0% 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

Lock the colour standard before grading. Once a shade moves, every downstream approval has to be redone and the calendar slips.

Planning something similar?

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