Capsule Sun Protection Boonie Hat in Crochet with High-Low Hem
Source:Sun Protection Boonie Hat /
Time:2026-09-30
Capsule Sun Protection Boonie Hat in Crochet with High-Low Hem
A Gym Chain approached us to develop a capsule sun protection boonie hat around a single idea: high-low hem, executed in crochet. The capsule was destined for Nigeria and needed capsule 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
- Decoration durability failed after two washes
- The sample did not match the runway reference
What we specified
| Product | Capsule Sun Protection Boonie Hat |
|---|---|
| Client type | A Gym Chain |
| Market | Nigeria |
| Order volume | 1,500 pieces across 3 colourways |
| Base material | Crochet |
| Signature detail | High-Low Hem |
| Size range | XS-3XL |
| Sampling rounds | 3 |
| Delivery window | 10 weeks from PO to ex-factory |
| Compliance | GOTS |
How it was built
- Reference garments and moodboards were translated into a measurement spec, not just photos.
- Crochet 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.
- High-Low 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
- 1,500 pieces delivered inside the 10-week window.
- Unit cost held within 3.0% of the approved quotation.
- The a Gym Chain 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?
Book a 20-minute call with our merchandising team and get a written quotation within 48 hours.
