Sculptural Ventilated Boonie Hat in Tulle with Raw-Edge Detailing

Sculptural Ventilated Boonie Hat in Tulle with Raw-Edge Detailing

A Coffee Roaster Chain approached us to develop a sculptural ventilated boonie hat around a single idea: raw-edge detailing, executed in tulle. The capsule was destined for the United States and needed sculptural 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
• The previous factory could not hold consistency across sizes
• Fabric hand feel changed between production runs

What we specified

How it was built

1. Reference garments and moodboards were translated into a measurement spec, not just photos.
2. Tulle was confirmed with lab dips and a hand-feel approval before grading.
3. The ventilated boonie hat was prototyped on the fit model, then revised twice before pre-production.
4. Raw-Edge Detailing 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

• 120 pieces delivered inside the 12-week window.
• Unit cost held within 3.0% of the approved quotation.
• The a Coffee Roaster Chain 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.