Rugby Top Customization Program for Aviation and Airlines with Pleating
Rugby Top Customization Program for Aviation and Airlines
This programme covers the full path from a rugby top concept to repeatable bulk supply for aviation and airlines. The build starts from everyday-casual references — rugby top in modal blend — then locks fabric weight, wash behaviour and fit tolerance so every reorder matches the approved sample.
Most rugby top buyers arrive with one of these problems: colour faded after a few washes, or the fabric felt thinner than the approved sample. The fix is a written spec before bulk: shrinkage allowance, stitch density, colour tolerance and a golden sample kept at the factory.
Specification
| Product | Rugby Top |
|---|---|
| Base fabric | Modal Blend |
| Decoration | Pleating |
| Fabric weight | 240-280 gsm |
| Fit options | XS-3XL |
| Colour options | 12 wash-stable shades |
| MOQ | 300 pieces per style per colour |
| Sampling | 12 working days, 4 days per revision |
| Bulk lead time | 25-40 days after approval |
| Compliance | GOTS |
What you can customise
- Reflective Printing — quoted per position and per colour on Modal Blend.
- Smocking — quoted per position and per colour on Modal Blend.
- Pleating — quoted per position and per colour on Modal Blend.
- Glow-in-the-Dark Printing — quoted per position and per colour on Modal Blend.
- Piece Dyeing — quoted per position and per colour on Modal Blend.
- Beading and Embroidery — quoted per position and per colour on Modal Blend.
- Flocking — quoted per position and per colour on Modal Blend.
How we produce it
- Tech pack review, fabric confirmation and lab dip approval
- Pattern, grading and a Modal Blend-spec prototype
- Fit sample and wearer test, then pre-production sign-off
- Bulk cutting with pleating applied under controlled settings
- In-line inspection, final AQL 2.5 check and packing
Quality control
Every bulk lot is compared against the approved sample for shade, hand feel, measurements and wash behaviour. Rugby Top reorders stay comparable over time because the spec, the lab dip and the golden sample are all on file.
FAQ
How long does sampling take?
A first prototype is typically ready in 12 working days after the tech pack is confirmed, including fabric sourcing if the base cloth is not in our stock library. Revisions add about 4 days each.
What is the minimum order quantity?
Standard programmes start at 300 pieces per style and colour. We can split sizes across a size set, and for first orders we often accept a mixed-colour run to help you test the market.
What file formats do you need for artwork?
Vector files (AI, EPS, PDF) give the best print and embroidery results. For raster artwork please supply at least 300 dpi at the final print size. We digitise embroidery files in-house and return a sew-out photo for approval.
Can you match a specific colour?
Yes. Send us a Pantone TCX reference or a physical swatch. We return lab dips for approval and hold bulk shade within the agreed tolerance band before cutting.
Start your rugby top programme
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.
