Tailored Men'S Fishing Boonie Hat in Merino Wool with Gathered Sleeves

Tailored Men'S Fishing Boonie Hat in Merino Wool with Gathered Sleeves

A Coffee Roaster Chain approached us to develop a tailored men's fishing boonie hat around a single idea: gathered sleeves, executed in merino wool. 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

• Delivery missed the collection launch window
• The sample did not match the runway reference
• Fabric hand feel changed between production runs

What we specified

How it was built

1. Reference garments and moodboards were translated into a measurement spec, not just photos.
2. Merino Wool was confirmed with lab dips and a hand-feel approval before grading.
3. The men's fishing boonie hat was prototyped on the fit model, then revised twice before pre-production.
4. Gathered Sleeves was applied in a controlled process to keep every piece consistent.
5. Bulk ran with in-line inspection; a photo report was shared before shipment.

Result

• 1,500 pieces delivered inside the 8-week window.
• Unit cost held within 1.5% of the approved quotation.
• The a Coffee Roaster 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?

Tell us the quantity, target price and delivery window, and we will build a customisation programme around those three numbers.