Custom Aviator in Mohair with 3D Puff Embroidery

Custom Aviator — Mohair with 3D Puff Embroidery

We build aviator programmes from a tech pack or a physical reference sample. This Mohair 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, 3d puff embroidery 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: minimum order quantities far above what a growing brand can absorb, or minimum order quantities far above what a growing brand can absorb. 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

• Ribbed Cuff and Hem — available on Mohair, quoted per position and per colour.
• DTF Film Printing — available on Mohair, quoted per position and per colour.
• Enzyme Wash — available on Mohair, quoted per position and per colour.
• Pleating — available on Mohair, quoted per position and per colour.
• Stone Wash — available on Mohair, quoted per position and per colour.
• Shirring — available on Mohair, quoted per position and per colour.
• Tonal Embroidery — available on Mohair, 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 Mohair-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with 3d puff embroidery applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Sports Teams and Clubs — aviator uniforms, staff wear or resale programmes
• Corporate Offices — aviator uniforms, staff wear or resale programmes
• Banking and Finance — aviator uniforms, staff wear or resale programmes
• Airlines and Cruise Lines — aviator uniforms, staff wear or resale programmes
• Manufacturing Plants — aviator 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 aviator batches stay comparable over time. Inspection photos and the measurement report are sent before the balance payment is due.

FAQ

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.

How long does sampling take?

A first prototype is typically ready in 10 working days after the tech pack is confirmed, including fabric sourcing if the base cloth is not in our stock library. Revisions add about 3 days each.

What is the minimum order quantity?

Standard programmes start at 100 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.

How is shipping handled?

We quote EXW, FOB, CIF and DDP. Consolidated sea freight is the default for bulk programmes, with air or express options when a launch date is at risk.

Start your aviator programme

Tell us the quantity, target price and delivery window, and we will build a customisation programme around those three numbers.