Sculptural Kids Aviator Hat in Ribbed Jersey with Asymmetric Closure
Source:Kids Aviator Hat /
Time:2026-09-30
Sculptural Kids Aviator Hat in Ribbed Jersey with Asymmetric Closure
A Beauty Salon Chain approached us to develop a sculptural kids aviator hat around a single idea: asymmetric closure, executed in ribbed jersey. The capsule was destined for Malaysia and needed sculptural 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
- Delivery missed the collection launch window
- Fabric hand feel changed between production runs
What we specified
| Product | Sculptural Kids Aviator Hat |
|---|---|
| Client type | A Beauty Salon Chain |
| Market | Malaysia |
| Order volume | 240 pieces across 2 colourways |
| Base material | Ribbed Jersey |
| Signature detail | Asymmetric Closure |
| Size range | XS-3XL |
| Sampling rounds | 4 |
| Delivery window | 8 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.
- Ribbed Jersey 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.
- Asymmetric Closure 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 8-week window.
- Unit cost held within 3.0% of the approved quotation.
- The a Beauty Salon Chain 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?
Share a reference photo or a sample garment and we will reverse-engineer the specification for your own label.
