Tailored Kids Aviator Hat in Tencel with Bow Detail
Source:Kids Aviator Hat /
Time:2026-09-30
Tailored Kids Aviator Hat in Tencel with Bow Detail
A Construction Firm approached us to develop a tailored kids aviator hat around a single idea: bow detail, executed in tencel. The capsule was destined for the United Arab Emirates and needed tailored 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
- Decoration durability failed after two washes
- Unit costs were too high for a boutique price point
- The previous factory could not hold consistency across sizes
What we specified
| Product | Tailored Kids Aviator Hat |
|---|---|
| Client type | A Construction Firm |
| Market | the United Arab Emirates |
| Order volume | 1,500 pieces across 5 colourways |
| Base material | Tencel |
| Signature detail | Bow Detail |
| Size range | XS-3XL |
| Sampling rounds | 3 |
| Delivery window | 12 weeks from PO to ex-factory |
| Compliance | WRAP |
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.
- Bow 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
- 1,500 pieces delivered inside the 12-week window.
- Unit cost held within 1.5% of the approved quotation.
- The a Construction Firm launched on schedule and reordered the same specification next season.
What we would repeat
Approve the hand feel on the actual bulk fabric — proto cloth always behaves differently.
Planning a similar capsule?
Book a 20-minute call with our merchandising team and get a written quotation within 48 hours.
