Luxe Kids Aviator Hat in Velvet with Gathered Sleeves
Source:Kids Aviator Hat /
Time:2026-09-30
Luxe Kids Aviator Hat in Velvet with Gathered Sleeves
An Independent Boutique Brand approached us to develop a luxe kids aviator hat around a single idea: gathered sleeves, executed in velvet. The capsule was destined for Ireland and needed luxe 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
- Decoration durability failed after two washes
- The previous factory could not hold consistency across sizes
What we specified
| Product | Luxe Kids Aviator Hat |
|---|---|
| Client type | An Independent Boutique Brand |
| Market | Ireland |
| Order volume | 240 pieces across 3 colourways |
| Base material | Velvet |
| Signature detail | Gathered Sleeves |
| Size range | XS-3XL |
| Sampling rounds | 3 |
| Delivery window | 12 weeks from PO to ex-factory |
| Compliance | BSCI |
How it was built
- Reference garments and moodboards were translated into a measurement spec, not just photos.
- Velvet 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.
- Gathered Sleeves 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
- 240 pieces delivered inside the 12-week window.
- Unit cost held within 3.0% of the approved quotation.
- The an Independent Boutique Brand 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?
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.
