Modern Kids Aviator Hat in Merino Wool with Raw-Edge Detailing
Source:Kids Aviator Hat /
Time:2026-09-30
Modern Kids Aviator Hat in Merino Wool with Raw-Edge Detailing
A Ski Resort approached us to develop a modern kids aviator hat around a single idea: raw-edge detailing, executed in merino wool. The capsule was destined for Portugal and needed modern 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
- Fabric hand feel changed between production runs
- Decoration durability failed after two washes
- Delivery missed the collection launch window
What we specified
| Product | Modern Kids Aviator Hat |
|---|---|
| Client type | A Ski Resort |
| Market | Portugal |
| Order volume | 2,400 pieces across 5 colourways |
| Base material | Merino Wool |
| Signature detail | Raw-Edge Detailing |
| Size range | XS-3XL |
| Sampling rounds | 3 |
| 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.
- Merino Wool 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.
- Raw-Edge Detailing 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 8-week window.
- Unit cost held within 2.0% of the approved quotation.
- The a Ski Resort launched on schedule and reordered the same specification next season.
What we would repeat
Lock the colour standard before grading; every downstream approval depends on it.
Planning a similar capsule?
Share a reference photo or a sample garment and we will reverse-engineer the specification for your own label.
