Elevated Sun Protection Boonie Hat in Tencel with Open Back
Source:Sun Protection Boonie Hat /
Time:2026-09-30
Elevated Sun Protection Boonie Hat in Tencel with Open Back
A Military Supply Unit approached us to develop a elevated sun protection boonie hat around a single idea: open back, executed in tencel. The capsule was destined for India and needed elevated 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
- Fabric hand feel changed between production runs
- The previous factory could not hold consistency across sizes
What we specified
| Product | Elevated Sun Protection Boonie Hat |
|---|---|
| Client type | A Military Supply Unit |
| Market | India |
| Order volume | 900 pieces across 5 colourways |
| Base material | Tencel |
| Signature detail | Open Back |
| Size range | 0-14 |
| 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.
- Tencel 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.
- Open Back 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
- 900 pieces delivered inside the 8-week window.
- Unit cost held within 3.0% of the approved quotation.
- The a Military Supply Unit 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?
Book a 20-minute call with our merchandising team and get a written quotation within 48 hours.
