Custom Hat Sun in Organic Cotton with Yarn Dyeing

Custom Hat Sun — Organic Cotton with Yarn Dyeing

We build hat sun programmes from a tech pack or a physical reference sample. This Organic Cotton version is developed for brands that need a repeatable specification: the same cloth, the same hand feel and the same fit on every reorder. Fabric, trims, yarn dyeing and packaging are all specifiable, so the garment stays consistent across seasons and across production runs.

Most buyers come to us after one of these problems: unclear responsibility when a defect shows up after washing, or color drift between lab dips and bulk fabric. Our response is to fix the specification first — fabric weight, shrinkage allowance, stitch density and tolerance — before a single bulk metre is cut.

Specification

What you can customise

• Dye-Sublimation Printing — available on Organic Cotton, quoted per position and per colour.
• Quilting — available on Organic Cotton, quoted per position and per colour.
• Beading and Embroidery — available on Organic Cotton, quoted per position and per colour.
• Piece Dyeing — available on Organic Cotton, quoted per position and per colour.
• Rhinestone Application — available on Organic Cotton, quoted per position and per colour.
• DTG Digital Printing — available on Organic Cotton, quoted per position and per colour.
• Flat Embroidery — available on Organic Cotton, quoted per position and per colour.

How we produce it

1. Tech pack review and fabric confirmation
2. Lab dips or print strike-off for approval
3. Pattern making, grading and a Organic Cotton-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with yarn dyeing applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Surf and Swim Brands — hat sun uniforms, staff wear or resale programmes
• Kidswear Subscription Boxes — hat sun uniforms, staff wear or resale programmes
• Restaurants and Cafes — hat sun uniforms, staff wear or resale programmes
• Chemical and Oil & Gas — hat sun uniforms, staff wear or resale programmes
• Healthcare and Hospitals — hat sun uniforms, staff wear or resale programmes

Quality control

Every bulk order is checked against the approved sample for shade, hand feel, measurements and workmanship. We record shrinkage, colour fastness and seam strength on the first bulk lot and hold the data as the reference for reorders, so hat sun batches stay comparable over time. Inspection photos and the measurement report are sent before the balance payment is due.

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 5 days each.

What is the minimum order quantity?

Standard programmes start at 500 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.

Do you provide compliance documents?

We can arrange OEKO-TEX, GOTS, BSCI, WRAP and ISO documentation as well as third-party testing reports for BSCI, and we support REACH, CPSIA and Prop 65 declarations for the relevant markets.

Start your hat sun 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.