Custom Work Caps in Merino Wool with DTF Film Printing

Custom Work Caps — Merino Wool with DTF Film Printing

We build work caps programmes from a tech pack or a physical reference sample. This Merino Wool 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, dtf film printing 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: color drift between lab dips and bulk fabric, 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

• DTG Digital Printing — available on Merino Wool, quoted per position and per colour.
• Enzyme Wash — available on Merino Wool, quoted per position and per colour.
• Padding and Wadding — available on Merino Wool, quoted per position and per colour.
• Pantone Color Matching — available on Merino Wool, quoted per position and per colour.
• Yarn Dyeing — available on Merino Wool, quoted per position and per colour.
• Laser Engraving — available on Merino Wool, quoted per position and per colour.
• Piping and Binding — available on Merino Wool, 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 Merino Wool-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with dtf film printing applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Motorcycle and Motorsport — work caps uniforms, staff wear or resale programmes
• Government and Municipal — work caps uniforms, staff wear or resale programmes
• Tennis Academies — work caps uniforms, staff wear or resale programmes
• Music Bands and Touring — work caps uniforms, staff wear or resale programmes
• Retail Store Staff — work caps 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 work caps batches stay comparable over time. Inspection photos and the measurement report are sent before the balance payment is due.

FAQ

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.

What is the minimum order quantity?

Standard programmes start at 200 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.

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.

Start your work caps programme

Share a reference photo or a sample garment and we will reverse-engineer the specification for your own label.