Custom Warm Caps in Gabardine with Applique Embroidery

Custom Warm Caps — Gabardine with Applique Embroidery

We build warm caps programmes from a tech pack or a physical reference sample. This Gabardine 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, applique 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: suppliers who disappear once the deposit is paid, or packaging that arrives crushed and unsellable. 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 Gabardine, quoted per position and per colour.
• All-Over Sublimation — available on Gabardine, quoted per position and per colour.
• Rhinestone Application — available on Gabardine, quoted per position and per colour.
• Quilting — available on Gabardine, quoted per position and per colour.
• Foil Printing — available on Gabardine, quoted per position and per colour.
• Garment Dyeing — available on Gabardine, quoted per position and per colour.
• Ruching — available on Gabardine, 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 Gabardine-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with applique embroidery applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Railway and Transit — warm caps uniforms, staff wear or resale programmes
• Sports Teams and Clubs — warm caps uniforms, staff wear or resale programmes
• Fashion Brands and Labels — warm caps uniforms, staff wear or resale programmes
• Maternity and Baby Care — warm caps uniforms, staff wear or resale programmes
• Wedding and Bridal — warm 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 warm caps batches stay comparable over time. Inspection photos and the measurement report are sent before the balance payment is due.

FAQ

Do you provide compliance documents?

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

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 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 warm caps programme

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