Case Study: Custom Plus Size Competition Swimsuits for a Shopify DTC Brand in Austria
Source:Plus Size Competition Swimsuits /
Time:2026-09-18
Plus Size Competition Swimsuits for a Shopify DTC Brand in Austria
A Shopify DTC Brand approached us with a plus size competition swimsuits requirement for Austria. 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
- No reliable way to track a order once it enters production
- Color drift between lab dips and bulk fabric
What we specified
| Product | Plus Size Competition Swimsuits |
|---|---|
| Client type | A Shopify DTC Brand |
| Market | Austria |
| Order volume | 2,000 pieces across 3 colourways |
| Base fabric | Organza |
| Decoration | Acid Wash |
| Size range | S-4XL |
| Sampling rounds | 3 |
| Delivery window | 12 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Organza and locked shrinkage allowance before grading.
- Decoration was moved to Acid Wash 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 12-week window.
- Unit cost held within 4.5% 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
Lock the colour standard before grading. Once a shade moves, every downstream approval has to be redone and the calendar slips.
Planning something similar?
Tell us the quantity, target price and delivery window, and we will build a customisation programme around those three numbers.
