Tailored Kids Aviator Hat in Tulle with Hand-Finished Hem
Source:Kids Aviator Hat /
Time:2026-09-30
Tailored Kids Aviator Hat in Tulle with Hand-Finished Hem
A Beauty Salon Chain approached us to develop a tailored kids aviator hat around a single idea: hand-finished hem, executed in tulle. The capsule was destined for Canada 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 Beauty Salon Chain |
| Market | Canada |
| Order volume | 240 pieces across 4 colourways |
| Base material | Tulle |
| Signature detail | Hand-Finished Hem |
| Size range | XS-3XL |
| Sampling rounds | 4 |
| Delivery window | 8 weeks from PO to ex-factory |
| Compliance | OEKO-TEX Standard 100 |
How it was built
- Reference garments and moodboards were translated into a measurement spec, not just photos.
- Tulle 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.
- Hand-Finished Hem 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 1.5% of the approved quotation.
- The a Beauty Salon Chain 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.
