Elevated Ventilated Boonie Hat in Merino Wool with Open Back
Source:Ventilated Boonie Hat /
Time:2026-09-30
Elevated Ventilated Boonie Hat in Merino Wool with Open Back
A Surf School approached us to develop a elevated ventilated boonie hat around a single idea: open back, executed in merino wool. The capsule was destined for Nigeria 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
- The sample did not match the runway reference
- Decoration durability failed after two washes
- Unit costs were too high for a boutique price point
What we specified
| Product | Elevated Ventilated Boonie Hat |
|---|---|
| Client type | A Surf School |
| Market | Nigeria |
| Order volume | 600 pieces across 5 colourways |
| Base material | Merino Wool |
| Signature detail | Open Back |
| Size range | 0-14 |
| Sampling rounds | 2 |
| Delivery window | 8 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 ventilated 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
- 600 pieces delivered inside the 8-week window.
- Unit cost held within 3.0% of the approved quotation.
- The a Surf School launched on schedule and reordered the same specification next season.
What we would repeat
Lock the colour standard before grading; every downstream approval depends on it.
Planning a similar capsule?
Share a reference photo or a sample garment and we will reverse-engineer the specification for your own label.
