Case Study: Custom Unisex Outdoor Cap for a University Athletic Department in Australia
Source:Unisex Outdoor Cap /
Time:2026-09-18
Unisex Outdoor Cap for a University Athletic Department in Australia
A University Athletic Department approached us with a unisex outdoor cap requirement for Australia. 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
- Long lead times that miss the selling season
- Inconsistent sizing between production runs
- Minimum order quantities far above what a growing brand can absorb
What we specified
| Product | Unisex Outdoor Cap |
|---|---|
| Client type | A University Athletic Department |
| Market | Australia |
| Order volume | 2,000 pieces across 6 colourways |
| Base fabric | Mulberry Silk |
| Decoration | Ultrasonic Welding |
| 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 Mulberry Silk and locked shrinkage allowance before grading.
- Decoration was moved to Ultrasonic Welding 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
- 2,000 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
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.
