Luxe Sun Protection Boonie Hat in Merino Wool with Open Back
Source:Sun Protection Boonie Hat /
Time:2026-09-30
Luxe Sun Protection Boonie Hat in Merino Wool with Open Back
A Golf Club approached us to develop a luxe sun protection boonie hat around a single idea: open back, executed in merino wool. The capsule was destined for Germany and needed luxe 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 previous factory could not hold consistency across sizes
- The sample did not match the runway reference
- Delivery missed the collection launch window
What we specified
| Product | Luxe Sun Protection Boonie Hat |
|---|---|
| Client type | A Golf Club |
| Market | Germany |
| Order volume | 1,500 pieces across 2 colourways |
| Base material | Merino Wool |
| Signature detail | Open Back |
| Size range | XS-XL |
| Sampling rounds | 2 |
| Delivery window | 10 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.
- Merino Wool 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
- 1,500 pieces delivered inside the 10-week window.
- Unit cost held within 1.5% of the approved quotation.
- The a Golf Club 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?
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.
