Tailored Plus Size Competition Swimsuits in Merino Wool with Covered Buttons

Tailored Plus Size Competition Swimsuits in Merino Wool with Covered Buttons

A Coffee Roaster Chain approached us to develop a tailored plus size competition swimsuits around a single idea: covered buttons, 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

• Unit costs were too high for a boutique price point
• Fabric hand feel changed between production runs
• Delivery missed the collection launch window

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 plus size competition swimsuits was prototyped on the fit model, then revised twice before pre-production.
4. Covered Buttons 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

• 600 pieces delivered inside the 10-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

Lock the colour standard before grading; every downstream approval depends on it.

Planning a similar capsule?

Send us your tech pack or even a rough sketch — we will come back with fabric options, a costed sample plan and a realistic production calendar.