Capsule Kids Aviator Hat in Crochet with Lace Inset
Source:Kids Aviator Hat /
Time:2026-09-30
Capsule Kids Aviator Hat in Crochet with Lace Inset
A Film Production House approached us to develop a capsule kids aviator hat around a single idea: lace inset, executed in crochet. The capsule was destined for Ireland and needed capsule finishing that reads designer on the rail while staying repeatable in bulk. This case study records the brief, the specification and the delivery.
The challenge
- The previous factory could not hold consistency across sizes
- Decoration durability failed after two washes
- Unit costs were too high for a boutique price point
What we specified
| Product | Capsule Kids Aviator Hat |
|---|---|
| Client type | A Film Production House |
| Market | Ireland |
| Order volume | 600 pieces across 4 colourways |
| Base material | Crochet |
| Signature detail | Lace Inset |
| Size range | XS-3XL |
| Sampling rounds | 2 |
| Delivery window | 8 weeks from PO to ex-factory |
| Compliance | GOTS |
How it was built
- Reference garments and moodboards were translated into a measurement spec, not just photos.
- Crochet was confirmed with lab dips and a hand-feel approval before grading.
- The kids aviator hat was prototyped on the fit model, then revised twice before pre-production.
- Lace Inset was applied in a controlled process to keep every piece consistent.
- Bulk ran with in-line inspection; a photo report was shared before shipment.
Result
- 600 pieces delivered inside the 8-week window.
- Unit cost held within 2.0% of the approved quotation.
- The a Film Production House launched on schedule and reordered the same specification next season.
What we would repeat
Keep one process owner on both sides. Most delays come from hand-offs, not machines.
Planning a similar capsule?
Share a reference photo or a sample garment and we will reverse-engineer the specification for your own label.
