Custom Hat Warm Set in Down-Proof Nylon with Laser Cutting

Custom Hat Warm Set — Down-Proof Nylon with Laser Cutting

We build hat warm set programmes from a tech pack or a physical reference sample. This Down-Proof Nylon 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, laser cutting 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: inconsistent sizing between production runs, or suppliers who disappear once the deposit is paid. 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 Down-Proof Nylon, quoted per position and per colour.
• Smocking — available on Down-Proof Nylon, quoted per position and per colour.
• 3D Puff Embroidery — available on Down-Proof Nylon, quoted per position and per colour.
• Chenille Embroidery — available on Down-Proof Nylon, quoted per position and per colour.
• Tonal Embroidery — available on Down-Proof Nylon, quoted per position and per colour.
• Seam Sealing — available on Down-Proof Nylon, quoted per position and per colour.
• Woven Label — available on Down-Proof Nylon, 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 Down-Proof Nylon-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with laser cutting applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Railway and Transit — hat warm set uniforms, staff wear or resale programmes
• Dance and Ballet Schools — hat warm set uniforms, staff wear or resale programmes
• Motorcycle and Motorsport — hat warm set uniforms, staff wear or resale programmes
• Ski and Snowboard Resorts — hat warm set uniforms, staff wear or resale programmes
• Gyms and Fitness Studios — hat warm set 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 warm set 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 14 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.

Do you provide compliance documents?

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

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 hat warm set programme

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