Case Study: Custom Plus Size Competition Swimsuits for a Film Production House in the United Arab Emirates

Plus Size Competition Swimsuits for a Film Production House in the United Arab Emirates

A Film Production House approached us with a plus size competition swimsuits requirement for the United Arab Emirates. 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

• Inconsistent sizing between production runs
• Packaging that arrives crushed and unsellable
• No reliable way to track a order once it enters production

What we specified

How it was resolved

1. We rebuilt the tech pack around Bamboo Viscose and locked shrinkage allowance before grading.
2. Decoration was moved to Glow-in-the-Dark Printing 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

• 500 pieces delivered inside the 6-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

Keep one process owner on both sides. Most delays come from hand-offs, not from machines.

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.