Case Study: Custom Old Fashioned Swimming Cap for a Shopify DTC Brand in Colombia
Source:Old Fashioned Swimming Cap /
Time:2026-09-18
Old Fashioned Swimming Cap for a Shopify DTC Brand in Colombia
A Shopify DTC Brand approached us with a old fashioned swimming cap requirement for Colombia. 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
- Minimum order quantities far above what a growing brand can absorb
- Long lead times that miss the selling season
- Inconsistent sizing between production runs
What we specified
| Product | Old Fashioned Swimming Cap |
|---|---|
| Client type | A Shopify DTC Brand |
| Market | Colombia |
| Order volume | 500 pieces across 2 colourways |
| Base fabric | Satin |
| Decoration | Quilting |
| Size range | 2-12Y |
| Sampling rounds | 2 |
| Delivery window | 10 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Satin and locked shrinkage allowance before grading.
- Decoration was moved to Quilting 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
- 500 pieces delivered inside the 10-week window.
- Unit cost held within 1.5% of the original quotation.
- Return rate linked to fit or workmanship stayed under 0.5%.
- 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?
Send us your tech pack or even a rough sketch — we will come back with fabric options, a costed sample plan and a realistic production calendar.
