Case Study: Custom Kids Aviator Hat for a Streetwear Collective in Morocco
Source:Kids Aviator Hat /
Time:2026-09-18
Kids Aviator Hat for a Streetwear Collective in Morocco
A Streetwear Collective approached us with a kids aviator hat requirement for Morocco. 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
- Suppliers who disappear once the deposit is paid
What we specified
| Product | Kids Aviator Hat |
|---|---|
| Client type | A Streetwear Collective |
| Market | Morocco |
| Order volume | 8,000 pieces across 4 colourways |
| Base fabric | Flame-Retardant Fabric |
| Decoration | Woven Label |
| Size range | 2-12Y |
| Sampling rounds | 4 |
| 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 Woven Label 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
- 8,000 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 1.0%.
- 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?
Tell us the quantity, target price and delivery window, and we will build a customisation programme around those three numbers.
