Boutique Uv Protection Cycling Hat in Merino Wool with Open Back

Boutique Uv Protection Cycling Hat in Merino Wool with Open Back

A Fast-Growing Startup Label approached us to develop a boutique uv protection cycling hat around a single idea: open back, executed in merino wool. The capsule was destined for China and needed boutique 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

• Fabric hand feel changed between production runs
• The previous factory could not hold consistency across sizes
• Unit costs were too high for a boutique price point

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 uv protection cycling hat was prototyped on the fit model, then revised twice before pre-production.
4. Open Back 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

• 240 pieces delivered inside the 10-week window.
• Unit cost held within 1.5% of the approved quotation.
• The a Fast-Growing Startup Label 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.