Custom Down Jacket in Pima Cotton with Dye-Sublimation Printing

Custom Down Jacket — Pima Cotton with Dye-Sublimation Printing

We build down jacket programmes from a tech pack or a physical reference sample. This Pima Cotton 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, dye-sublimation 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: no reliable way to track a order once it enters production, or no reliable way to track a order once it enters production. 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

• Quilting — available on Pima Cotton, quoted per position and per colour.
• Piece Dyeing — available on Pima Cotton, quoted per position and per colour.
• Dye-Sublimation Printing — available on Pima Cotton, quoted per position and per colour.
• Seam Sealing — available on Pima Cotton, quoted per position and per colour.
• Laser Engraving — available on Pima Cotton, quoted per position and per colour.
• Beading and Embroidery — available on Pima Cotton, quoted per position and per colour.
• Satin Printed Label — available on Pima Cotton, 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 Pima Cotton-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with dye-sublimation printing applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Surf and Swim Brands — down jacket uniforms, staff wear or resale programmes
• Maternity and Baby Care — down jacket uniforms, staff wear or resale programmes
• Motorcycle and Motorsport — down jacket uniforms, staff wear or resale programmes
• Aviation and Airlines — down jacket uniforms, staff wear or resale programmes
• Film and TV Production — down jacket 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 down jacket 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 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.

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 is the minimum order quantity?

Standard programmes start at 50 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.

Start your down jacket programme

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