Bohemian Kids Aviator Hat in Merino Wool with Gathered Sleeves
Source:Kids Aviator Hat /
Time:2026-09-30
Bohemian Kids Aviator Hat in Merino Wool with Gathered Sleeves
A Trade Show Exhibitor approached us to develop a bohemian kids aviator hat around a single idea: gathered sleeves, executed in merino wool. The capsule was destined for Mexico and needed bohemian 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
- Unit costs were too high for a boutique price point
- Decoration durability failed after two washes
What we specified
| Product | Bohemian Kids Aviator Hat |
|---|---|
| Client type | A Trade Show Exhibitor |
| Market | Mexico |
| Order volume | 240 pieces across 4 colourways |
| Base material | Merino Wool |
| Signature detail | Gathered Sleeves |
| Size range | XS-XL |
| Sampling rounds | 4 |
| Delivery window | 8 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.
- 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.
- 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 8-week window.
- Unit cost held within 2.0% of the approved quotation.
- The a Trade Show Exhibitor 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.
