Case Study: Custom Quick Dry Surf Rash Guard for a Cycling Team in Japan
Source:Quick Dry Surf Rash Guard /
Time:2026-09-18
Quick Dry Surf Rash Guard for a Cycling Team in Japan
A Cycling Team approached us with a quick dry surf rash guard requirement for Japan. 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
- Minimum order quantities far above what a growing brand can absorb
What we specified
| Product | Quick Dry Surf Rash Guard |
|---|---|
| Client type | A Cycling Team |
| Market | Japan |
| Order volume | 500 pieces across 2 colourways |
| Base fabric | Recycled Polyester (rPET) |
| Decoration | Contrast Stitching |
| Size range | Custom grading |
| Sampling rounds | 3 |
| Delivery window | 5 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Recycled Polyester (rPET) and locked shrinkage allowance before grading.
- Decoration was moved to Contrast Stitching 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 5-week window.
- Unit cost held within 1.5% 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
Keep one process owner on both sides. Most delays come from hand-offs, not from machines.
Planning something similar?
Tell us the quantity, target price and delivery window, and we will build a customisation programme around those three numbers.
