Capsule Kids Aviator Hat in Tencel with Cut-Out Detail
Source:Kids Aviator Hat /
Time:2026-09-30
Capsule Kids Aviator Hat in Tencel with Cut-Out Detail
A Pet Grooming Franchise approached us to develop a capsule kids aviator hat around a single idea: cut-out detail, executed in tencel. The capsule was destined for Czechia 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 sample did not match the runway reference
- Fabric hand feel changed between production runs
- Unit costs were too high for a boutique price point
What we specified
| Product | Capsule Kids Aviator Hat |
|---|---|
| Client type | A Pet Grooming Franchise |
| Market | Czechia |
| Order volume | 2,400 pieces across 4 colourways |
| Base material | Tencel |
| Signature detail | Cut-Out Detail |
| Size range | Custom grading |
| Sampling rounds | 4 |
| Delivery window | 6 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.
- Tencel 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.
- Cut-Out Detail 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
- 2,400 pieces delivered inside the 6-week window.
- Unit cost held within 3.0% of the approved quotation.
- The a Pet Grooming Franchise 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?
Book a 20-minute call with our merchandising team and get a written quotation within 48 hours.
