Custom Clothing Pads in Alpaca with Ultrasonic Welding

Custom Clothing Pads — Alpaca with Ultrasonic Welding

We build clothing pads programmes from a tech pack or a physical reference sample. This Alpaca 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, ultrasonic welding 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: packaging that arrives crushed and unsellable, 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

• Flat Embroidery — available on Alpaca, quoted per position and per colour.
• 3D Puff Embroidery — available on Alpaca, quoted per position and per colour.
• Quilting — available on Alpaca, quoted per position and per colour.
• Padding and Wadding — available on Alpaca, quoted per position and per colour.
• Woven Label — available on Alpaca, quoted per position and per colour.
• Tie-Dye Wash — available on Alpaca, quoted per position and per colour.
• Ribbed Cuff and Hem — available on Alpaca, 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 Alpaca-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with ultrasonic welding applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Wholesale and Distribution — clothing pads uniforms, staff wear or resale programmes
• Chemical and Oil & Gas — clothing pads uniforms, staff wear or resale programmes
• Yoga and Pilates Studios — clothing pads uniforms, staff wear or resale programmes
• Motorcycle and Motorsport — clothing pads uniforms, staff wear or resale programmes
• Restaurants and Cafes — clothing pads 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 clothing pads 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.

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.

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 5 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.

Start your clothing pads programme

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