Statement Ventilated Boonie Hat in Merino Wool with Tonal Embroidery
Source:Ventilated Boonie Hat /
Time:2026-09-30
Statement Ventilated Boonie Hat in Merino Wool with Tonal Embroidery
A Ski Resort approached us to develop a statement ventilated boonie hat around a single idea: tonal embroidery, executed in merino wool. The capsule was destined for Japan and needed statement 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 sample did not match the runway reference
- The previous factory could not hold consistency across sizes
What we specified
| Product | Statement Ventilated Boonie Hat |
|---|---|
| Client type | A Ski Resort |
| Market | Japan |
| Order volume | 2,400 pieces across 3 colourways |
| Base material | Merino Wool |
| Signature detail | Tonal Embroidery |
| Size range | 0-14 |
| Sampling rounds | 2 |
| Delivery window | 8 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.
- 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.
- Tonal Embroidery 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
- 2,400 pieces delivered inside the 8-week window.
- Unit cost held within 2.0% of the approved quotation.
- The a Ski Resort 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.
