Runway-Inspired Sun Protection Boonie Hat in Merino Wool with Cut-Out Detail

Runway-Inspired Sun Protection Boonie Hat in Merino Wool with Cut-Out Detail

A Cruise Line approached us to develop a runway-inspired sun protection boonie hat around a single idea: cut-out detail, executed in merino wool. The capsule was destined for the United Arab Emirates and needed runway-inspired 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
• The previous factory could not hold consistency across sizes
• The sample did not match the runway reference

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 sun protection boonie hat was prototyped on the fit model, then revised twice before pre-production.
4. Cut-Out Detail 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

• 2,400 pieces delivered inside the 6-week window.
• Unit cost held within 1.5% of the approved quotation.
• The a Cruise Line 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.