Bohemian Sun Protection Boonie Hat in boucle with Hand-Finished Hem
Source:Sun Protection Boonie Hat /
Time:2026-09-30
Bohemian Sun Protection Boonie Hat in boucle with Hand-Finished Hem
A Film Production House approached us to develop a bohemian sun protection boonie hat around a single idea: hand-finished hem, executed in boucle. The capsule was destined for Spain 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
- The sample did not match the runway reference
- Fabric hand feel changed between production runs
- Delivery missed the collection launch window
What we specified
| Product | Bohemian Sun Protection Boonie Hat |
|---|---|
| Client type | A Film Production House |
| Market | Spain |
| Order volume | 240 pieces across 5 colourways |
| Base material | boucle |
| Signature detail | Hand-Finished Hem |
| Size range | Custom grading |
| Sampling rounds | 2 |
| Delivery window | 12 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.
- boucle was confirmed with lab dips and a hand-feel approval before grading.
- The sun protection boonie 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 12-week window.
- Unit cost held within 3.0% of the approved quotation.
- The a Film Production House launched on schedule and reordered the same specification next season.
What we would repeat
Keep one process owner on both sides. Most delays come from hand-offs, not machines.
Planning a similar capsule?
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